FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications .......................................................................................... 7 1
Description ............................................................................................... 7 2
Removal and Installation ...................................................................... 7 3
Front Wheels (Tires) .................................................................................. 7 3
Front Axle and Reduction Differential Assembly ........................................ 7 5
Reduction Differential Assembly ................................................................ 7 7
Front Axle ................................................................................................. 7 9
Disassembly .............................................................................................. 7 9
Inspection .................................................................................................. 7 12
Reassembly ............................................................................................... 7 14
Reduction Differential ........................................................................... 7 17
Disassembly .............................................................................................. 7 17
7
Inspection .................................................................................................. 7 19
Reassembly ............................................................................................... 7 21
Troubleshooting ...................................................................................... 7 28
Service Data ............................................................................................ 7 29
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications

Truck Model
DP100 DP115 DP135 DP150
Item
Type Full-floating, tubular
Front axle
Housing type Banjo

Gear type Hypoid

Reduction
bevel gear
Gear ratio 5.571

Type Planetary gear

Final
drives
Gear ratio 4.167

Differential bevel gear,

Straight bevel 2
type No. of gears
Differential
Differential bevel pinion,
Straight bevel 4
type No. of pinions

7-1
FRONT AXLE AND REDUCTION DIFFERENTIAL

Description

5 1 6 3 2 9 10 11 8

12

15

14 16 13
210370

1. Front wheel hub 9. Differential bevel gear

2. Front axle housing 10. Differential bevel pinion
3. Axle shaft 11. Reduction bevel gear
4. Ring gear 12. Reduction bevel pinion
5. Planet gear 13. Input flange
6. Wheel brake assembly 14. Parking brake drum
7. Reduction and differential assembly 15. Parking brake bracket
8. Differential case 16. Parking brake assembly

The front axle is of full-floating type with banjo-type axle

housing of all-welded construction. It is bolted to the front
side of the frame. The final drives are of planetary gear
type. The wheel brake assemblies are mounted on the axle
housing. The parking brake assembly is mounted on the
input flange fitted to the reduction bevel pinion.

7-2
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal and Installation

Front Wheels (Tires)

Removal
6
Sequence 5
1. Extension bracket 4
2. Wheel nuts
7
3. Clamp 1
4. Wedge band
5. Front wheel (Tire) (outer)
6. Spacer
7. Extension valve 8 2
8. Front wheel (Tire) (inner) 3
210371

Start by:
Loosen the outer wheel nuts about two full turns, and block
the rear wheels.

Truck lifting
(1) Lifting with lift equipment
Tilt backward Tilt forward
Tilt the mast fully backward, place wood blocks under
the mast, and tilt the mast forward.

WARNING
After raising the front end of the truck, securely
support the truck by putting wood blocks under
the frame. Block the rear wheels.

Wood
block
210372
(2) Tire removal
(a) Position the extension valve at top center.
(b) Release air from the tire.

(c) Hammer and remove the wedge band with a dolly

NOTE
Air is compressed. Keep your face away.

bar applied to it.

210373

7-3
FRONT AXLE AND REDUCTION DIFFERENTIAL

(d) Front tire removal

Support the front tires with the fork of a lift truck
or the Tire Handler (special tool). Remove outer
wheel nuts and detach the front tire.
Special tool needed

Tire handler Banzai WD-5500

210374

(e) Extension valve removal

Draw out the inner tire as far as the end of the
brake hub, and remove the extension valve of the
air valve.

210375

Installation
Follow the reverse of removal sequence and do the
following steps.
(1) Install the inner tire into place.
(a) Make sure that the air valve set groove in the hub
1 4
and the positioning boss on the rim meet.
(b) After the tire goes in as far as the end of the brake 6 7
hub, fit the extension valve to the air valve.
9 -LE
VE 2
(c) Push the inner tire further into place. To prevent L-

the tire from falling, put a scotch block under it.

(2) Tighten wheel nuts evenly to specified torque in the 3 10
numerical order shown at the right. 8 5
210376
53949 Nm
Tightening torque (555 kgfm)
[39836 lbfft]

(3) After installing the tires, retighten wheel nuts.

After about 10 minutes of advancing, reversing and
braking, check wheel nuts for the specified torque
using a torque wrench.

7-4
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle and Reduction Differential Assembly

Removal

2
4
210378

Sequence
1. Wheel brake pipes (left and right) 4. Front axle and reduction differential assembly,
2. Parking brake cable, Nut Bolts, Nuts, Washers
3. Universal joint

Start by:
(1) Mast assembly removal
(a) Disconnect piping and electrical wiring from the
mast assembly.
(b) Hitch a shackle and a sling to the hanger on top of
the outer mast, and hoist the front of the frame to
lift the front tires off the floor.
(c) Place an appropriate stand or square timber under
the front of the frame to prevent falling.
(d) Put scotch blocks under the rear tires.
(e) With the outer mast lifted off the floor, disconnect 210377
the tilt cylinder at the rod side.
(f) Remove the mast assembly. (For details, refer to
GROUP 12 MASTS AND FORKS.)
(2) Removing front tires
Refer to (d) Front tire removal on page 7-4.
7-5
FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Removal

(1) After disconnecting the wheel brake pipes, cover the
openings to prevent dirt from getting inside the brake
lines.
(2) Disconnect the universal joint at the input flange side.
Transmission
Before disconnecting the joint, fasten it to the Disconnect here.
transmission with rope to prevent it from falling.
Remember that the oil will flow out of the transmission
case when the joint is removed.
(3) To remove the front axle and reduction and differential
assembly, fasten a hoist to the axle housing by hitching
chains or wires to the mast supports. When hitching
such slings, be sure to use a protective rag to prevent
damage to these supports.
204585A

Installation
Follow the reverse of removal sequence and do the
following steps:
(1) Tighten the bolts to the specified torque.

64096 Nm
Tightening torque for front
(65.39.8 kgfm)
axle housing mounting bolts
[47271 lbfft]

(2) After having installed the parking brake wire, check to

make sure that the lever operating effort is within the
specified range.

245 to 294 N
Parking brake lever operating
(25 to 30 kgf)
effort
[55 to 66 lbf]

(3) After having installed the wheel brake pipes, bleed the
brake lines, and check them for leakage. It is advisable
that this work be performed before the front wheels and
mast are installed.

NOTE: For the procedure to bleed the brake lines, refer to

GROUP 9 BRAKE SYSTEM.

7-6
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential Assembly

Removal
Remove the front axle and reduction differential assembly
from the frame, then remove the parking brake and
reduction differential assembly from the front axle.

210379

Sequence
1. Wheel hub cover, Gasket, Bolts, Washers 3. Reduction differential assembly, Bolts,
2. Axle shafts, Sun gear, Snap ring Washers

Start by:
Remove the drain plugs from the axle housing and the
planet carrier and drain the oil

Suggestions for Removal

(1) Axle shaft removal
Remove each axle shaft with the sun gear.
(2) Lay the axle housing with the differential side up.
(3) To remove the differential assembly, install two eye
bolts to the universal joint mounting bolt holes and
fasten a hoist to these eye bolts.

7-7
FRONT AXLE AND REDUCTION DIFFERENTIAL

Installation
Follow the reverse of removal sequence.

Suggestions for Installation

(1) When installing the differential assembly, check to
make sure the mounting surfaces of the differential
assembly and the front axle housing are clean and free
from any defect. Apply ThreeBond No. 1215 to these
surfaces.

Bolt length 11812 Nm

37 mm (12.01.2 kgfm)
Tightening torque (1.46 in.) [879 lbfft]
for reduction
differential bolts Bolt length 13214 Nm
31 mm (13.51.4 kgfm)
(1.22 in.) [9810 lbfft]

(2) Install the wheel hub cover with new gasket. Tighten
the bolts to the specified torque.

576 Nm
Tightening torque for
(5.80.6 kgfm)
wheel hub cover bolts
[424 lbfft]

(3) Install the front axle to the frame and fill the axle with
oil.
On one side of the axle, position the wheel hub so that
-LEVEL- mark on the wheel hub cover is horizontal.
Remove the level plug from a cover on which it is
horizontal. On the other cover, remove the drain or
the level plug whichever is above horizontal. Then
remove the level plug on the differential side of the
axle housing and fill the housing through this plug
hole. The oil used in the axle housing is high in
viscosity and will not flow out soon even if leakage
occurs. With this kept in mind, tighten all the plugs
securely. 210380

Recommended oil Hypoid gear oil SAE #90

Refill capacity 25 liters (6.6 U.S. gal.)

7-8
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle

Disassembly

6
4

3
2 4

1
210381

Sequence
1. Plug, Gasket 6. Ring gear, Taper roller bearing (inner race)
2. Cover, Gasket, Bolts, Washers 7. Hub drum assembly, Front wheel hub, Stud,
3. Planet carrier assembly, Planet carrier, O-rings, Brake drum, Stud bolts, Washers, Nuts, Taper
Planet pins, Steel balls, Thrust washers, roller bearing (outer race), Oil seal,
Planet gears, Bushings Oil deflector, Bolts, Washers
4. Axle shaft, Sun gear, Sleeve, Snap ring 8. Taper roller bearing (inner race),
5. Lock plates, Bolts, Washers, Nuts Oil seal retainer, O-ring

NOTE
The oil can be drained with the axle housing on the
truck.

7-9
FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly

1. Oil draining
Place a dip pan to catch the oil that flows from the axle
housing when the plug is removed and when the planet
carrier assembly is removed.

2. Planet carrier assembly removal

Remove the bolts holding the planet carrier assembly.
Screw two wheel hub cover bolts into the removal holes in
the carrier evenly to force out the planet carrier assembly.

210382

3. Planet gear removal

Remove the pins to remove the planet gears. Be careful not
to lose the steel balls.

210383

4. Nut removal
144 (5.67) 65 (2.56)
Unit: mm (in.)
Use the Socket Wrench (special tool) and an impact wrench 72 (2.83) 25 (0.98)
to remove the nut. 3
(0.12)
Special tool needed
(0 20
9)
162 (6.38)

75 (2.95)
)

65 (2.56)

.7
2

155
.0

Socket wrench 92267 - 00200

(6
3

(6.10)
15

(0 2.7
0)
1
.5

19 (0.75)
60 (2.36)
5. Axle shaft removal 30 (1.18)
90 (3.54)
Turn a sliding hammer in the M10 x 1.25 hole at the end of 205603A
the axle shaft to remove the axle shaft.

7-10
 FRONT AXLE AND REDUCTION DIFFERENTIAL

6. Hub drum assembly removal

Support the hub drum assembly with a transmission jack.
Remove the front wheel hub with a wheel hub puller.

210384

7. Bearing removal
Using a bearing puller, remove the inner race of the taper
roller bearing from the axle housing, along with the seal
retainer.

204590

NOTE
For disassembly, inspection and assembly of the wheel
brakes mounted on the axle housing, refer to GROUP
9 BRAKE SYSTEM.

7-11
FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection

1. Axle shafts
Set a dial indicator at the middle part of the axle shaft, and
rotate the shaft to measure the deflection.
B: Repair or service limit
Unit: mm (in.)
Deflection of axle shaft
(1/2 of dial indicator reading) B 1.0 (0.039)

200860

2. Axle housing
(1) Check the mast support bearing contact surfaces for
wear or damage.
(2) Check the outer and inner oil seals for wear or damage.
(3) Check the axle housing for distortion, dents or other
defects. Also check the welds for cracks.

3. Hub and drum assemblies

(1) Check the oil seal for wear or damage.
(2) Check the inside surface of the brake drum for wear or
damage.
A: Standard value B: Repair or service limit
Unit: mm (in.)
A 420 + 00.2 (16.54 + 00.008 )
Inside diameter of wheel
brake drum
B 424 (16.69)

(3) Check the taper roller bearings (outer races) for wear or
damage.

7-12
 FRONT AXLE AND REDUCTION DIFFERENTIAL

4. Planet carriers
(1) Measure the inside diameter of the planet gear rollers
and the diameter of the planet pins.
A: Standard value B: Repair or service limit
Unit: mm (in.)
58 ++ 0.029
0.010

Inside diameter of planet A (2.28 ++ 0.00114

0.00039 )

gear rollers
B 57.96 (2.2819)
0
50 0.011
A 0
(1.97 0.00043 )
Diameter of planet pins
B 49.96 (1.9669)

(2) Check the thrust washers for wear or damage.

A: Standard value B: Repair or service limit
Unit: mm (in.)
1.20.06
A
(0.0470.0024)
Thickness of thrust washer
B 0.8 (0.031)

5. Others
(1) Check the outer surface of oil seal retainer for wear or
damage.
(2) Check the taper roller bearings (inner races) for wear or
damage.

7-13
FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

11

9 10 5 6 7 8 4 3 2
210385

Sequence
1. Front axle housing
2. Oil seal retainer, O-ring
3. Taper roller bearing (inner race)
4. Hub and drum assembly, Front wheel hub,
Studs, Brake Drum, Studs, Washers, Nuts,
Taper roller bearing (outer race), Oil seal, Oil
deflector, Bolts, Washers
5. Ring gear, Taper roller bearing (inner race)
6. Nut
7. Lock plate, Bolts, Washers
8. Sleeve, Axle shaft
9. Planet carrier assembly, Planet carrier, Planet
gears, Bushings, Thrust washers, Planet pins,
Steel balls, O-ring, Bolt, Washers
10. Sun gear, Snap ring
11. Cover, Gasket, Bolts, Washers

7-14
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Start by:
(a) Assemble the planet carrier.
(b) When assembling the hub and drum assembly after Liquid gasket
replacing the parts, align the extension valve grooves in
the brake drum and wheel hub.
(c) Use liquid gasket on the mating surface of the oil
deflector when installing the deflector.

35936 Nm
Tightening torque for brake
(36.63.7 kgfm)
drum nuts
[26527 lbfft]

210386
NOTE

Replace the oil seals of the front axle housing.

Suggestions for Reassembly

1. Taper roller bearing (inner race) installation

Using an installer, install the taper roller bearing inner race
in position, along with the oil seal retainer.

204592

7-15
FRONT AXLE AND REDUCTION DIFFERENTIAL

2. Wheel hub bearing preload adjustment

Hook a spring scale to one of the hub bolts. Pull the scale
in tangential direction and take a reading on the scale just
when the hub begins to rotate. Adjust the preload by
means of the nut that holds the ring gear. The preload
decreases after a period of months, it is advisable to aim at
a value of preload in the lower half of the range.

Preload for wheel hub 118 to 157 N

bearing (force applied in (12 to 16 kgf)
210387
tangential direction) [26 to 35 lbf]

NOTE

Adjust the hub bearing preload every 2400 hours or 1

year.

3. Planet gear installation

(1) Put the needle roller bearing in position in each planet
gear. Put the thrust washers on both sides of each gear
and install the gears with the pin in the carrier. Lock
the gear in position with a steel ball.

210388

(2) Install the planet carrier to the wheel hub and, after
making sure the hub rotates freely, tighten its mounting
bolts to the specified torque.

9310 Nm
Tightening torque for
(9.51.0 kgfm)
planet carrier bolts
[697 lbfft]

210389

7-16
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential

Disassembly

10

4
2
5 4

1
4
4
4 5
2

210390

Sequence
1. Bolts, Washers, Lock plates 6. Nut, Washer, O-ring
2. Side bearing nuts 7. Input flange, Parking brake drum, Reamer
3. Differential carrier, Cap set, Bolts, Lock bolts, Washers, Nuts, Dust plug
washers, Bearing caps, Differential carrier 8. Parking brake assembly, Bolts, Nuts, Washers
4. Differential bevel gear assembly, Reduction 9. Parking brake bracket, Oil seal, O-ring, Bolts,
bevel gear, Spider, Differential bevel pinions, Washers
Differential bevel gears, Washers, 10. Reduction bevel pinion, Oil separator, Taper
Differential case, Bolts, Nut roller bearings, Collar, Bearing retainer,
5. Taper roller bearings Shim(s), O-ring, Roller bearings, Stopper

7-17
FRONT AXLE AND REDUCTION DIFFERENTIAL

NOTE
(1) For disassembly, inspection and assembly of the
parking brake assembly, refer to GROUP 9
BRAKE SYSTEM.
(2) Replace the oil seal of the parking brake bracket.

Suggestions for Disassembly

NOTE
(1) Before disassembling the differential, measure the
gear backlash to aid in assembling the differential
correctly.

Backlash between reduction 0.25 to 0.33 mm

bevel gear and bevel pinion (0.0098 to 0.0130 in.)

(2) Put a mark across the bearing cap and carrier on

210391
one side to ensure correct refitting.
(3) When removing the bearing retainer from the
differential carrier, make a record of the thickness
or amount of shim(s) between the retainer and
carrier.

210392

7-18
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection

1. Reduction bevel gear and reduction bevel pinion

Check the reduction bevel gear and reduction bevel pinion
for tooth contact. Check the gear teeth for wear, pitting,
flaking or chipping. Minor flaws on the tooth surfaces can
be repaired by grinding with an oil stone or a sand paper. If
the gear is badly damaged to require replacement, replace
the gear and pinion as a set.

2. Differential
(1) Check the differential case for damage. Check, in
particular, the seat formed of each case for carrying the
taper roller bearing inner race to see whether the seat
surface is fretted or not.
(2) Check the sliding surfaces of the washers and gears for
wear or damage.
(3) Check the teeth of the differential bevel pinions and
bevel gears for wear, pitting, chipping, galling, etc.
(4) Check the play of each pinion on the shaft.
A: Standard value B: Repair or service limit
Unit: mm (in.)
0.169 to 0.278
Play between differential A
(0.00665 to 0.01094)
bevel pinion inner diameter
and shaft outer diameter
B 0.35 (0.0138)

(5) Check the free movement of the differential bevel gears

on the axle shafts (looseness of mating splines).
B: Repair or service limit
Unit: mm (in.)

Free movement of differential

bevel gears on axle shafts B 0.5 (0.020)
(looseness of mating splines)

7-19
FRONT AXLE AND REDUCTION DIFFERENTIAL

3. Parking brake drum

(1) Check the inside surface of the drum for wear or
damage.
(2) Replace the drum if its inside diameter is in excess of
the service limit.

A: Standard value B: Repair or service limit

Unit: mm (in.)
304.8 + 00.5
A
(12.000 + 00.020 )
Inside diameter of brake drum
B 307 (12.09)

7-20
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

11

10
12

9
9

8 7

6
2

13
5
3
1
210393

Sequence
1. Differential case, Washers, Differential bevel 7. Bearing retainer, Taper roller bearing (outer
gears, Differential bevel pinions, Pinion shafts, race), O-ring, Shim(s)
Washers , Bolts 8. Taper roller bearing (inner race), Oil separator
2. Reduction bevel gear, Bolts, Nuts 9. Parking brake bracket, Oil seal, O-ring, Bolts,
3. Taper roller bearings Washers
4. Differential carrier, Bearing caps, 10. Parking brake assembly, Bolts, Washers
Lock washers, Bolts 11. Input flange, Parking brake drum, Reamer
5. Side bearing nuts bolts, Washers, Nuts, Plug
6. Reduction bevel pinion, Taper roller bearing 12. Self-locking nut, Washers, O-ring
(inner race), Collar 13. Lock plates, Bolts, Washers

7-21
FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Reassembly

1. Differential case assembling

The backlash between the differential bevel gear and bevel
pinion is to be adjusted by means of the washers of the
differential bevel gear. If the backlash is in excess of the
service limit, replace the washers.

A: Standard value B: Repair or service limit

Unit: mm (in.)
0.2 to 0.28
A
Backlash between differential (0.008 to 0.0110)
bevel gear and bevel pinion
B 0.5 (0.020) 210394

2. Differential case installation

Apply LOCTITE No. 271 to the bolts that hold the
differential case and tighten the bolts to the specified
torque.

19629 Nm
Tightening torque for
(203 kgfm)
differential case bolts
[14522 lbfft]

3. Reduction bevel gear installation

To install the reduction bevel gear, put LOCTITE No. 271
on the threads of the mounting bolts, and tighten the bolts
evenly to the specified torque.

Tightening torque for 44169 Nm

reduction bevel gear (457 kgfm)
mounting bolts [32551 lbfft]

4. Side bearing cap installation

The bearing caps are machined together with the
differential carrier. Identify the left and right caps by
referring to the marks. Fit the caps tentatively by
tightening the cap bolts finger tight. The caps are to be
secured tight after the preload for the differential case taper
roller bearing and the tooth contact of the reduction bevel
gear and bevel pinion have been adjusted.

379 to 512 Nm
Tightening torque for side
(38.6 to 52.2 kgfm)
bearing cap bolts
[279 to 378 lbfft]

7-22
 FRONT AXLE AND REDUCTION DIFFERENTIAL

5. Differential case side bearing preload adjustment

(1) Check the preload for the taper roller bearing with the Side bearing
differential case off the truck before installing the
reduction bevel pinion. Tie a wire around the
periphery A of the differential case, and hook a spring
scale to the wire. Pull the scale in tangential direction A
and take a reading on the spring scale just when the
case begins to rotate. The preload can be adjusted by
means of the left and right bearing nuts.

NOTE
Tighten the side bearing nuts equally so as not to 210395

disturb the backlash. Before measuring the preload,

tap the back of the reduction bevel gear with a copper-
face hammer while rotating the gear by hand for
running-in.

245 to 343 Nm
(25 to 35 kgfcm)
[180 to 253 lbfft]
23 to 32 N
Preload for differential
(2.3 to 3.3 kgf)
case side bearing
[5.2 to 7.2 lbf]
as force applied to
periphery A of differential
case in tangential direction

6. Reduction bevel pinion bearing preload

adjustment Fixed

(1) Tentatively assemble the reduction bevel pinion by

installing the parts 6, 7, 8, 11 and 12 in that order.
(2) Tighten the self-locking nut to the specified torque.
29429 Nm
(303.0 kgfm)
29429 Nm [21721 lbfft)
Tightening torque for self-
(303.0 kgfm)
locking nut
[21721 lbfft] Fixed
210396

7-23
FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Hold the input flange in a vise. Hook a spring scale to

the bolt hole of the bearing retainer. Pull the spring
scale in tangential direction and take a reading on the
spring scale just when the retainer begins to turn.

30 to 43 N Collar
(3.1 to 4.4 kgf)
Preload for reduction bevel [6.8 to 9.7 lbf]
pinion bearing as force applied to
bearing retainer in
tangential direction
204602
The preload can be adjusted by means of the collar.
The collars are available in twenty-five different
thicknesses. When assembling the reduction bevel
pinion without replacing any parts, adjust the preload
to 80% of the standard value.
7. How to determine the required thickness of
shim(s) when the reduction bevel gear and
reduction bevel pinion are replaced
(1) Temporarily assemble the reduction bevel pinion.
(2) After checking the preload, measure actual value b of
dimension B.
(3) Find difference c between the standard value of A B
dimension B [53.5 mm (2.1063 in.)] and the actual
measurement.
c = 53.5 mm (2.1063 in.) b
210736
Note: (a) Round the thickness to the nearest tenth in
case of mm unit, and to the nearest ten-
thousandth in case of in. unit.
(b) When actual value b of dimension B is larger
than the standard value, c becomes a negative
value.
(4) Determine the required thickness A of shim(s) by the
following formula.
A = 0.5 mm (0.0197 in.) + c
Note: Round the thickness to the nearest tenth in case
of mm unit, and to the nearest ten-thousandth in
case of in. unit.
(5) Combine shims to install so that the thickness
determined above will be achieved.

Shims Unit: mm
Part No. Thickness
92331 03500 0.2 (0.0079)
92331 03600 0.1(0.0039)

7-24
 FRONT AXLE AND REDUCTION DIFFERENTIAL

8. Reduction bevel gear and bevel pinion tooth

contact and backlash adjustment
(1) Tentatively install the reduction bevel pinion in the
differential carrier as outlined in the preceding item
5. Reduction bevel pinion bearing preload adjustment.
(2) Put the original amount of the shim(s) in position, and
tentatively secure the bearing retainer.
(3) Move the reduction bevel gear toward the bevel pinion
BACKLASH
to obtain the correct backlash. To
increase.
Backlash between reduction 0.25 to 0.33 mm To decrease.
bevel gear and bevel pinion (0.0098 to 0.0130 in.)

To
NOTE decrease.

Turn in or out the left and right side bearing nuts To increase. BACKLASH
equally, or the preload will vary.
To increase.

To decrease.
205611

(4) Set up a dial indicator with its spindle pointing

squarely to the tooth face of reduction bevel gear. With
the bevel pinion held, move the gear back and forth to
observe the indicator.

210397

(5) Put a small amount of coloring paste on three or four

reduction bevel gear teeth on both concave and convex
faces. Press forward on the bevel pinion, and rotate the
reduction bevel gear back and forth until a contact
pattern is noted on both the concave and convex faces
of the gear teeth. To adjust the tooth contact, refer to
the following chart.

210398

7-25
FRONT AXLE AND REDUCTION DIFFERENTIAL

Tooth Contact Patterns and Adjustment

Tooth Contact Adjustment

Extends from top
to middle portion,
1 covering not less Correct tooth contact
than 50% of tooth
length

Short contact at top 1. Move gear away from pinion.

of tooth 1 2. Move pinion toward gear by
2 2 increasing shim thickness to secure
correct backlash.

Short contact at 1. Move gear toward pinion.

bottom of tooth 2 2. Move pinion away from gear by
3 decreasing shim thickness to
1
secure correct backlash.

Heavy contact on 1. Move pinion toward gear by

top half (adden- 2 increasing shim thickness.
4 dum) of tooth 2. Move gear away from pinion to
secure correct backlash.
1

Heavy contact on 1. Move pinion away from gear by

bottom half 2 decreasing shim thickness.
5 (dedendum) of 1 2. Move gear toward pinion to secure
tooth correct backlash.

204606

NOTE
For top contact or bottom contact, observe contacts on the outer side (convex face) of the reduction bevel gear for
judgment. For top half contact or bottom half contact, repeat the steps above for adjustment until satisfactory tooth
contact is obtained.

7-26
 FRONT AXLE AND REDUCTION DIFFERENTIAL

9. Oil seal installation

Installer Unit: mm (in.)
Using an installer, put the oil seal in the parking brake
bracket with the main lip toward the inside. Apply grease
and oil to the lips of the seal. 35

(5.12)
( 1.38)

130
Special tool needed
95 -0.1
0 0
( 3.74 -0.004 )

(0.91)
Oil seal installer (To be made by dealer)

(0.59)

23
15
68.50.1
( 2.700.004) 210399

10. Reduction and differential assembly installation

Apply retaining compound (ThreeBond No. 1215) to the
mounting face of the reduction and differential assembly,
and install the assembly to the front axle housing.

7-27
FRONT AXLE AND REDUCTION DIFFERENTIAL

Troubleshooting

Reduction bevel gear teeth badly worn Replace.

Gear noise comes out
continuously during driving
Bearing preload incorrect, or bearings worn Readjust or replace.
excessively
Hub bearings damaged Replace.
Reduction bevel pinion and reduction bevel gear Readjust.
tooth contact incorrect

Reduction bevel gear bearing or hub bearings Replace.

broken
Irregular noise comes out Differential bevel gear teeth broken, or thrust Replace gears or
during normal driving washers worn washers.
Metal piece in axle housing Clean and replace oil.
Axle shaft or differential carrier bolts loose Retighten.

Fit of differential bevel gears in differential Replace worn parts.

Abnormal noise comes out case out of specification due to wear
when turning a corner
Differential bevel pinion or side gear teeth Replace defective parts.
broken, or pinions seized on spider

Bearings damaged due to incorrect preload Replace bearings and

Differential overheats readjust preload.
Backlash between bevel pinion gear and Readjust tooth contact
reduction bevel gear incorrect and backlash.

Oil level too low or bad quality of oil Replace. (Refer to

Recommended
Abnormal noise from final Brands of Lubricants.)
drive
Planet gear teeth badly worn or chipping Replace.
Planet gear pin bushings abnormally worn Replace.

7-28
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Service Data

Front Axle
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item
Deflection of axle shaft 1
A 1.0 (0.039)
(1/2 of dial indicator reading)

Preload for hub bearings 2 (force applied to hub

A 118 to 157 (12 to 16) [26 to 35]
bolt in tangential direction) N (kgf) [lbf]

Tightening torque for brake drum nuts 3

A 35936 (36.63.7) [26527]
Nm (kgfm) [lbfft]

Tightening torque for brake backing plate

A 15616 (15.91.6) [11512]
mounting nuts 4 Nm (kgfm) [lbfft]

Tightening torque for front axle housing

A 64096 (65.39.8) [47271]
mounting nuts 5 Nm (kgfm) [lbfft]

Tightening torque for wheel nuts 6

A 53949 (555.0) [39836]
Nm (kgfm) [lbfft]

Tightening torque for wheel nuts 7

A 29429 (303) [21721]
Nm (kgfm) [lbfft]
0 0
A 50 0.011 (1.97 0.00043 )
Diameter of planet pin 8
B 49.96 (1.9669)

A 58 ++ 0.029 + 0.00114
0.010 (2.28 + 0.00039 )

Inside diameter of planet gear bearing 9

B 57.96 (2.2819)

A 1.20.06 (0.0470.0024)
Thickness of thrust washer 10
B 0.8 (0.031)

Tightening torque for cover bolts 11

A 576 (5.80.6) [424]
Nm (kgfm) [lbfft]

Tightening torque for lock plate bolts 12

A 172 (1.70.2) [121]
Nm (kgfm) [lbfft]

Tightening torque for deflector bolts 13

A 333 (3.40.3) [252]
Nm (kgfm) [lbfft]]

A 420 + 00.2 (16.54 + 00.008 )

Inside diameter of brake drum 14
B 424 (16.69)

7-29
FRONT AXLE AND REDUCTION DIFFERENTIAL

Truck Model
DP100 DP115 DP135 DP150
Item

9 10 2 3 4 1 5

Front axle

6 11 12 13 14

LEVEL

210402

7-30
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model
DP100 DP115 DP135 DP150
Item

Backlash between differential bevel gear and bevel A 0.2 to 0.28 (0.008 to 0.0110)
pinion 1 B 0.5 (0.020)
Play between differential bevel pinion inner diameter A 0.169 to 0.278 (0.00665 to 0.01094)
and shaft outer diameter 2 B 0.35 (0.0138)
Preload Nm (kgfm) [lbfft] A 245 to 343 (25 to 35) [180 to 253]
Differential Force applied to periphery A of
case bearing 3 differential case in tangential A 23 to 32 (15 to 30) [1.1 to 2.2]
direction N (kgf) [lbf]
Backlash between reduction bevel gear and
A 0.25 to 0.33 (0.0098 to 0.0130)
bevel pinion 4

Free movement of differential gear on axle shaft A

(looseness of mating splines) 5 B 0.5 (0.020)
Tightening torque for nuts 6 of reduction bevel gear A 44169 (457) [32551]
mounting bolts Nm (kgfm) [lbfft] (Apply LOCTITE No. 271.)
Tightening torque for side bearing cap bolts 7
A 379 to 512 (38.6 to 52.2) [279 to 378]
Nm (kgfm) [lbfft]
Bolt length
Tightening torque for differential A 11812 (12.01.2) [879]
37 mm (1.46 in.)
carrier mounting bolts 8
Nm (kgfm) [lbfft] Bolt length
A 13214 (13.51.4) [9810]
31 mm (1.22 in.)
Tightening torque for self-locking nut 9
A 29429 (303) [21722]
Nm (kgfm) [lbfft]
Force applied to bearing retainer in tangential
direction 10
A 30 to 43 (3.1 to 4.4) [6.8 to 9.7]
(preload for reduction bevel pinion bearing)
N (kgf) [lbf]
Tightening torque for differential case bolts 11 19629 (203) [14522]
A
Nm (kgfm) [lbfft] (Apply LOCTITE No. 271.)
Tightening torque for brake drum nuts 12
A 9615 (9.81.5) [7111]
Nm (kgfm) [lbfft]
Tightening torque for support plate nuts 13
A 14522 (14.82.2) [10716]
Nm (kgfm) [lbfft]
A 304.8 + 00.5 (12.000 + 00.020 )
Inside diameter of brake drum 14
B 307 (12.09)

7-31
FRONT AXLE AND REDUCTION DIFFERENTIAL

Truck Model
DP100 DP115 DP135 DP150
Item

12

13

14

10
6

11 8

Reduction
differential

5 7
3 2 1

210403

7-32