TROUBLESHOOTING SPECIAL TOOL ASSEMBLY AND ADJUSTMENT

Transcription

1 1 INDEX Models FD, FE, FF and SG REAR AXLE E-07 CHAPTER 10 REAR AXLE Models FD, FE, FF and SG TROUBLESHOOTING SPECIAL TOOL WHEEL HUB AND RELATED PARTS DISASSEMBLY INSPECTION ASSEMBLY AND ADJUSTMENT DIFFERENTIAL CARRIER (For Models FD and FE) HINO SH14-1 series Single speed Single reduction DIFFERENTIAL CARRIER (For Models FF and SG) HINO SH16-1 series Single speed Single reduction

2 10-2 REAR AXLE Models FD, FE, FF and SG TROUBLESHOOTING Symptom Possible cause Remedy Abnormal noise Bearing system Worn or damaged pinion bearings... Replace bearings Worn or damaged differential side bearings... Replace bearings Loose pinion bearings... Adjust bearing preload Loose differential side bearings... Adjust bearing preload Gear system Inadequate backlash on ring gear and pinion gear... Adjust backlash Worn thrust washers... Replace Worn differential spider... Replace Worn or damaged ring gear and pinion... Replace Worn or damaged differential side gears and pinions... Replace Loose ring gear tightening bolts... Tighten bolts Inadequate tooth contact of ring gear and pinion gear... Replace or adjust tooth contact Worn pinion spiine... Replace Rear axle system Worn rear axle shaft spline... Replace Worn hub bearings... Replace Loose hub bearings... Adjust bearing preload Loose differential case tightening bolts... Tighten bolts Oil system, etc. Insufficient oil... Add Poor oil quality... Change Abnormal noise of propeller shaft... Refer to CHAPTER 9 PROPELLER SHAFT

3 Models FD, FE, FF and SG REAR AXLE 10-3 SPECIAL TOOL Prior to starting a rear axle overhaul, it is necessary to have those special tools. Illustration Tool No. Tool name Model FD FE FF SG WHEEL HUB PULLER FD HUB NUT WRENCH FE FF SG HUB BEARING PULLER ADJUSTER TOOL SOCKET WRENCH HANDLE

4 10-4 REAR AXLE Models FD, FE, FF and SG Illustration Tool No. Tool name SOCKET WRENCH PINION DEPTH GAUGE

5 7 1 8 Models FD, FE, FF and SG REAR AXLE 10-5 WHEEL HUB AND RELATED PARTS NOTE: The illustrations and the text are based on FE and FF vehicles. In the case of FD and SG vehicles, there are several differences in the number of hub bolts and the shapes of the components. However, the operation procedures are the same except where specified. From the 1999 model year, all FD, FE, FF and SG vehicles are equipped with ABS (Antilock Brake System). As a result, the operation procedures for taking off and putting on the wheel hubs are very different. Please read this chapter carefully before working on these vehicles. Model FD SM Oil seal 2. Collar 3. Taper roller bearing 4. Hub 5. Lock washer 6. Lock nut 7. Lock plate 8. Axle shaft 9. Hub bolt nut 10. Oil deflector 11. Hub bolt 12. Wheel nut inner 13. Wheel nut outer 14. Air breather 15. Plug 16. Washer 17. Rear axle housing assembly 18. Differential carrier assembly 19. ABS sensor ring Fig. 1

6 10-6 REAR AXLE Models FD, FE, FF and SG Models FE, FF and SG SM Oil seal 2. Collar 3. Taper roller bearing 4. Hub 5. Lock washer 6. Lock nut 7. Lock plate 8. Axle shaft 9. Hub bolt nut 10. Oil deflector 11. Hub bolt 12. Wheel nut inner 13. Wheel nut outer 14. Air breather 15. Plug 16. Washer 17. Rear axle housing assembly 18. Differential carrier assembly 19. ABS sensor ring Fig. 2

7 Models FD, FE, FF and SG REAR AXLE 10-7 DISASSEMBLY 1. REMOVAL OF REAR WHEELS NOTE: Refer to CHAPTER 16, WHEEL AND TIRE. 2. DISASSEMBLY OF WHEEL HUB AND RELATED PARTS 1. Remove the brake drum set bolts, and then remove the drum from the wheel hub. Fig. 1 SM WARNING Do not work on brake drum while it is still hot, this can result in personal injury. The drums are heavy. The rear drum for model FD weighs 30 kg (66 lb), for models FE, FF weighs 40 kg (88 lb), and for model SG weighs 44 kg (97 lb). Be careful not to drop them. To assure safety, do this operation with more than two persons. 2. Loosen and remove the bolts, and then remove the axle shaft. SM Fig Remove the oil seal, and then loosen the bolts and remove the lock plate. SM Fig. 3 MODEL FD MODELS FE, FF AND SG 4. Remove the taper roller bearing lock nut using a special tool, and then remove the lock washer. Fig. 4 SM SM Special Tool: For model FD: Hub nut wrench ( ) For models FE, FF and SG: Hub nut wrench ( ) Handle ( )

8 10-8 REAR AXLE Models FD, FE, FF and SG Fig. 5 SM Using a special tool, remove the wheel hub with the outer taper roller bearing from the axle housing. Special Tool: Wheel hub puller ( ) for model FD ( ) for model FE, FF and SG WARNING The wheel hub assembly is heavy. The rear wheel hub assembly for model FD weighs 20 kg (44 lb), for models FE, FF and SG weighs 30 kg (66 Ib). Be careful not to drop it. To assure safety, do this operation with more than two persons. 6. Using a special tool, remove the inner taper roller bearing with oil seal collar from the axle housing. Special Tool: Hub bearing puller ( ) Handle ( ) or ( ) Fig. 6 SM Models FD, FE and FF Model SG 7. Remove the ABS wheel sensor. After removing the harness connector for the ABS wheel sensor and the cable clip, remove the ABS wheel sensor with its holder. NOTE: Subjecting the wheel sensor to a strong shock can cause internal damage. Do not strike the wheel sensor with a hammer or bump it against other components. Models FD,FE and FF Model SG 8. Remove the wheel brake. NOTE: Refer to CHAPTER 13, SERVICE BRAKE. Fig. 7 SM SM10-407

9 Models FD, FE, FF and SG REAR AXLE 10-9 INSPECTION 1. INSPECTION OF THE WHEEL HUB 1. Inspect the taper roller bearing with race for burns or pitting, and replace it if such defects are found. Fig. 1 SM Inspect the taper roller bearing race for burns, cracks, or brinelling on the raceways, and replace it if such defects are seen. NOTE: The bearing and the bearing race must be replaced as a set. Fig. 2 SM Replacement of taper roller bearing race. a. Remove the taper roller bearing race from the hub bore. Fig. 3 SM b. Install the new taper roller bearing race in the hub bore. Fig. 4 SM10-504A 4. Inspect the hub bolts. Replace the bolts if the threads of the bolts are worn or damaged. Fig. 5 SM10-505

10 10-10 REAR AXLE Models FD, FE, FF and SG 5. Replacement of hub bolt a. Loosen the hub bolt nuts and remove the hub bolts from the wheel hub. SM Fig. 6 b. Install the new hub bolts in place on the wheel hub. NOTE: The left and right hub bolts differ, so install them according to the chart below. Marks on the end Color A RIGHT R gold LEFT L silver Fig. 7 SM SM Tightening Torque : 4,000-4,800 kg cm ( lb ft) A : Stake NOTE: Stake the lock nuts at the two points after tightened to the specified torque. 6. Inspect the oil seal collar for wear. If the collar is excessively worn at the point of contact with the lip of the oil seal, replace it. SM Fig Inspect the axle shaft spline for wear or damage. If the spline is excessively worn or damaged, replace the shaft. SM Fig. 9

11 Models FD, FE, FF and SG REAR AXLE Inspect the axle tube. If the tube is abnormally worn or damaged at the point of contact with the lip of the oil seal, replace the axle housing. Fig. 10 SM Sensor ring Visually inspect for any damage or deformation of the sensor ring or protrusion from the wheel hub, etc. If there is any damage or deformation, replace the sensor ring. If the sensor ring is protruding from the wheel hub, push it in using a press board. Fig. 25 a. Removal of the sensor ring Uniformly tap on the periphery of the sensor ring using a screw driver or the like and remove it slowly. NOTE: When tapping and removing the sensor ring, be careful not to damage the wheel hub. Fig. 12 Fig. 13 PRESS BOARD GAP SENSOR RING ADHESION b. Installation of the sensor ring 1) Set the sensor ring in the wheel hub and uniformly push equally using a press board. NOTE: Warming up the sensor ring with warm water before pushing it in enables the procedure to be carried out smoothly. Never use a gas burner. Doing so can cause the sensor ring to be deformed. 2) After pushing it in, check the axle direction wobble of the sensor ring. Standard range: Under 0.2 mm ( in.) 8. Clamp bushing 1. Check that the wheel sensor is firmly secured. 2. If the wheel sensor can be pulled out or pushed in easily, replace the clamp bushing. Fig. 14

12 10-12 REAR AXLE Models FD, FE, FF and SG Fig. 1 For models FD, FE and FF SM For model SG SM ASSEMBLY AND ADJUSTMENT 1. ASSEMBLY AND ADJUSTMENT OF THE WHEEL HUB 1. Install the wheel brake assembly to the axle-housing. NOTE: Refer to CHAPTER 13, SERVICE BRAKE. The installation of the ABS wheel sensor is not proceeded. For models FD, FE and FF Tightening Torque: 1,500-2,000 kg cm ( lb ft) For model SG Tightening Torque: 1,700-2,300 kg cm ( lb ft) Fig. 2 Fig. 3 SM SM Apply wheel bearing grease to the taper roller bearing. Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. 3. Apply wheel bearing grease to the wheel hub. Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. Capacity; For model FD: 420 grams (15 oz) per wheel For model FE, FF and SG: 800 grams (28 oz) per wheel 4. Install the oil seal collar and inner taper roller bearing on the axle housing. WARNING When hammering, a metal tip may fly off on impact. Wear safety glasses to protect your eyes. Fig. 4 Models FD,FE and FF Model SG SM NOTE: This procedure must be performed after the ABS wheel sensor has been removed. 5. Install the ABS wheel sensor. After applying a thin film of chassis grease to the wheel sensor body, press the wheel sensor into the clamp bushing (holder) until the tip of the wheel sensor and the side surface of the holder become flat and install the holder on the base portion of the axle tube and tighten with the specified torque. Tightening torque: kg.cm (25-38 lb ft) Fig. 5

13 Models FD, FE, FF and SG REAR AXLE NOTE: The bolts should be tightened by hand. Never use an impact wrench. In this condition, the wheel sensor is still temporarily installed and should be finally installed after the pre-load adjustment of the wheel hub assembly. 6. Install the wheel hub and taper roller bearing (outer) on the axle housing. Fig. 6 WARNING Wheel hub assembly is heavy. The rear wheel hub assembly for model FD weighs 20 kg (44 lb), for model FE, FF and SG weighs 30 kg (66 Ib). Be careful not to drop it. To assure safety, do this operation with more than two persons. NOTE: Before installing the wheel assembly, clean the surface of the ABS sensor ring. The installation of the wheel assembly should be done calmly and straight in order not to apply an impact to the ABS wheel sensor. The installation of the outer wheel bearing should be done calmly using the bearing lock nuts. Never hammer the bearing in as is customary. 7. Install the lock washer and lock nut. a. Tighten the nut to the specified torque using a special tool while turning the wheel hub. Fig. 7 MODEL FD SM MODELS FE, FF AND SG Special Tool: For model FD: Hub nut wrench ( ) For models FE, FF and SG: Hub nut wrench ( ) Tightening Torque: 5,000-6,000 kg cm ( lb ft) b. Loosen the lock nut by 1/4 to 1/3 turn using a special tool. Fig. 8 SM SM10-498

14 10-14 REAR AXLE Models FD, FE, FF and SG Fig. 9 Fig. 10 SM SM c. Pull the wheel hub using the special tool in order to fit the bearing. NOTE: Since this procedure is performed in order not to apply an impact to the ABS wheel sensor, never hammer the bearing as is customary. Special tool: Wheel hub puller ( ) for model FD ( ) for models FE, FF and SG d. Measure the wheel bearing preload. Adjust the preload with the lock nut, if it exceeds or is less than specifications. [For model FD] Standard preload: kg.cm ( lb ft) (Turning torque) Spring balance value: kg ( lb) (Turning force) [For models FE, FF and SG] Standard preload: kg.cm ( lb ft) (Turning torque) Spring balance value: kg ( lb) (Turning force) Fig. 11 SM e. Apply the lock plate and align it with the small screw hole of the nut. If the hole does not align, turn over the plate. If alignment is still unattainable, turn the lock nut further within the limits of hub turning torque. Tightening Torque: For model FD: kg cm ( lb ft) For models FE, FF and SG: kg cm (14-18 lb ft) 8. Install the oil seal on the wheel hub. Fig. 12 SM10-519

15 Models FD, FE, FF and SG REAR AXLE Install the axle shaft in the wheel hub and tighten the set bolts to the specified torque. Tightening Torque: 870-1,100 kg cm (63-79 lb ft) Fig. 13 Models FD, FE and FF Fig. 14 Model SG SM Positioning the ABS wheel sensor a. Temporarily remove the brake lining of the wheel sensor installation side. The drum cover must be removed on SG vehicles. b. Fully depress the wheel sensor until it makes contact with the wheel sensor ring. c. Restore the brake lining. On SG vehicles, install the drum cover. NOTE: Refer to Chapter 13, SERVICE BRAKE. Fig. 15 SENSOR RING HUB WHEEL SENSOR MAKE CONTACT CLAMP BUSHING Fig. 16

16 10-16 REAR AXLE Models FD, FE, FF and SG Fig. 17 SM Install the brake drum on the wheel hub and tighten the drum set bolts. Tightening Torque: kg cm (15-28 lb ft) NOTE: Before installing the drum, fully retract the brake adjuster so that the outer diameter of the lining becomes minimum. WARNING The drums are heavy. The rear drum for model FD weighs 30 kg (66 lb), for models FE and FF weighs 40 kg (88 lb), and for model SG it weighs 44 kg (97 lb). To assure safety, do this operation with more than two persons. 2. INSTALLATION OF THE REAR WHEELS NOTE: Refer to CHAPTER 16, WHEEL AND TIRE. 3. FOR MODELS FD, FE AND FF BRAKE SYSTEM AIR BLEEDING AND BRAKE SHOE CLEARANCE ADJUSTMENT. 1. On completion of the wheel hub and related parts reassembly, conduct the following. a. Bleed the air from the brake lines according to section FINAL CHECK AND ADJUSTMENT in CHAP- TER 13, SERVICE BRAKE. b. Adjust the brake shoe clearance according to section INSPECTION AND ADJUSTMENT in CHAPTER 13, SERVICE BRAKE. 4. FOR MODEL SG BRAKE CHAMBER ROD STROKE On completion of the real axle reassembly, adjust the brake chamber rod stroke according to the section INSPECTION AND ADJUSTMENT in CHAPTER 13, SERVICE BRAKE.

17 Models FD and FE (SH14-1 Series) REAR AXLE DIFFERENTIAL CARRIER (HINO SH14-1 series for models FD and FE) Flange lock nut 2. Flange yoke coupling 3. Dust deflector 4. Oil seal 5. Taper roller bearing 6. Bearing cage 7. Shim 8. Name plate 9. Spacer 10. Drive pinion 11. Cylindrical roller bearing 12. Retainer ring 13. Differential carrier case 14. Adjust nut 15. Differential case 16. Side gear thrust washer 17. Side gear 18. Pinion thrust washer 19. Pinion 20. Spider 21. Ring gear 22. Collar 23. Bearing cap 24. Lock plate SM10-419A Fig. 1

18 10-18 REAR AXLE Models FD and FE (SH14-1 Series) REMOVAL 1. REMOVAL OF DIFFERENTIAL CARRIER NOTE: Be sure to apply wheel stoppers in the front and rear of the front tires. Fig. 2 SM Disconnect the propeller shaft from the flange at the differential carrier. NOTE: Draw the aligning marks on the flange and yoke before disassembling. Fig. 3 SM10-421B 2. Remove the filler and the drain plug to drain the gear oil from the axle housing. WARNING Do not work on differential carrier while it is still hot. This can result in personal injury. Fig. 4 Model FD Model FE SM Remove the bolts, and then pull the axle shafts out. Fig. 5 Fig. 6 SM SM10-489A SM10-424C 4. Use a jack to dismount the differential carrier assembly from the axle housing. WARNING When loosening the tightening bolts of the differential carrier, do not place yourself under the differential carrier. Be sure to apply a support before dismounting the differential carrier assembly.

19 Models FD and FE (SH14-1 Series) REAR AXLE DISASSEMBLY 1. DISASSEMBLY OF THE DIFFERENTIAL CARRIER 1. Mount the differential carrier assembly on a work stand. Fig. 7 SM10-425B 2. Loosen the bolts, then remove the bearing cap from the differential carrier. NOTE: First apply match marks to the cap and carrier. Special Tool: Socket wrench ( ) Fig. 8 SM10-426A 3. Remove the differential case assembly from the carrier. Fig. 9 SM Remove the taper roller bearings at both ends of the differential case by using a puller. Fig. 10 SM NOTE: Do not change the combination of the assembled taper roller bearing and its race. Always replace the bearings with their original races. 5. Loosen the bolts and remove the ring gear from the differential case. NOTE: Be careful not to drop the ring gear from the differential case. Fig. 11 SM10-429

20 10-20 REAR AXLE Models FD and FE (SH14-1 Series) 6. Disassemble the differential case. NOTE: Be sure to check the aligning marks on the differential case before disassembly. Remove the bolts so that the case separates. SM Fig Loosen the bolts and remove the pinion assembly, and then remove the cylindrical roller bearing from the differential carrier. Fig. 13 SM10-432B SM Remove the lock nut using a special tool. Spread the staking of the nut completely with a chisel, then loosen the nut. NOTE: Insufficient spread of the staked parts will cause damage to the threads of the drive pinion when loosening the nut. Special Tool: Socket wrench ( ) Fig. 14 SM10-434A SM10-435A 9. Separate the bearing cage and the pinion gear with a press. Fig. 15 SM Remove the taper roller bearing from the pinion gear using a puller. Fig. 16 SM10-437

21 Models FD and FE (SH14-1 Series) REAR AXLE Remove the retainer ring and then pull out the inner race for cylindrical roller bearing from the pinion gear using a puller. WARNING The retainer ring is spring steel and may pop out. Wear safety glasses to protect your eyes. Fig. 17 SM SM Remove the oil seal and the taper roller bearing outer races from the cage. NOTE: At the same time that the bearing is drawn out, the oil seal comes out. Be careful not to deform the oil seal. SM Fig. 18 INSPECTION 1. INSPECTION OF THE DIFFERENTIAL CARRIER 1. Check the flange coupling spline for wear and damage. Replace the coupling if damaged or worn. SM10-442A Fig Inspect the taper roller bearings, cylindrical roller bearing and races for burns or pitting. If such defects are found, replace it. SM SM Fig. 20 Fig. 21 SM10-445A 3. Inspect the drive pinion and ring gear teeth surfaces for wear, stripping or damage, and replace both parts as a set when defects are found. NOTE: The drive pinion and ring gear must be replaced as a set, not individually, because they are fitted to each other by lapping during manufacture. Replacement of only one part does not produce proper tooth contact, and gear strength drops excessively.

22 10-22 REAR AXLE Models FD and FE (SH14-1 Series) 4. Inspect the spider holes and surfaces of the differential case that come in contact with the thrust washers for wear or damage. Replace the case, if damaged or worn. Fig. 22 SM Inspect the pinion for wear or damage and check the amount of wear of the bore with a cylinder gauge. Fig. 23 Fig. 24 SM SM Inspect the spider for damage, and check the amount of wear by measuring its journals with a micrometer to determine the spider to pinion clearance. When the clearance is beyond the service limit, replace it. Standard clearance: Service limit: mm ( in.) 0.4 mm (0.016 in.) 7. Measure the thickness of the thrust washers on the pinion and side gears. Replace any washer worn beyond the limit. Standard Thickness: Side gear mm ( in.) Pinion gear mm ( in.) Fig. 25 SM10-449A SM Service Limit: Side gear Pinion gear 1.3 mm (0.051 in.) 1.3 mm (0.051 in.)

23 Models FD and FE (SH14-1 Series) REAR AXLE Measure the pinion backlash by using a dial gauge with a magnet base. When the backlash is beyond the service limit, replace the pinion gear and/or side gear. Fig. 26 SM Assembly standard: Service limit: mm ( in.) 0.90 mm ( in.) Put the side gear in the differential case so that the chamfering surface of the thrust washer is on the gear side. A A A 9. Measure the backlash of the side gear and pinion with the cogs of the pinion and side gear in the position shown in Fig. 27, D. A Pinion B Side gear B C B CORRECT B INCORRECT C Thrust washer D Correct E Incorrect Fig. 27 SM10-269B

24 10-24 REAR AXLE Models FD and FE (SH14-1 Series) Fig. 1 SM SM ASSEMBLY 1. ASSEMBLY AND ADJUSTMENT OF DIFFERENTIAL CARRIER 1. Assemble the differential case. NOTE: Align the aligning marks on cases. Tighten the bolts to the specified torque. Apply the lock agent (Lock tight) which is equivalent to THREE BOND: 1360K on threads. Tightening Torque: 1,700-2,200 kg cm ( lb ft) 2. Install the ring gear to the differential case. NOTE: Apply the lock agent (Lock tight) which is equivalent to THREE BOND: 1360K on threads. SM Fig Tighten the bolts to the specified torque. Tightening Torque: 3,700-4,300 kg cm ( lb ft) SM Fig Install the taper roller bearing to both ends of the differential case using a press. SM Fig Install the cylindrical roller bearing inner race using a press and install the retainer ring on the end of the drive pinion. WARNING The retainer ring is spring steel and may pop out. Wear safety glasses to protect your eyes. Fig. 5 SM SM10-458

25 Models FD and FE (SH14-1 Series) REAR AXLE Using a press, install the inner taper roller bearing to the drive pinion. Fig. 6 SM Using a press, install the taper roller bearing outer races in the bearing cage. Fig. 7 SM SM Put the spacer to drive pinion. Fig. 8 SM10-582A 9. Using a press, assemble the bearing cage and taper roller bearing on the drive pinion. Fig. 9 SM Install the flange on the pinion shaft without oil seal, and then tighten the flange lock nut to the specified torque using a special tool. Special Tool: Socket wrench ( ) Tightening Torque: 6,000-8,000 kg cm ( lb ft) Fig. 10 SM10-464A

26 10-26 REAR AXLE Models FD and FE (SH14-1 Series) Fig. 11 SM10-465A 11. Measure the preload of the drive pinion bearings. If the preload is out of the specified limits, adjust it as follows. Use a thinner spacer to increase and a thicker one to decrease preload. When new bearings, use the spacer of mm (0.558 in.) at first and measure the preload. This will be helpful to select the spacer for specified preload. Tighten the flange lock nut to the specified torque before re-checking. a. Using a torque wrench. New bearing Re-used bearing Turning torque kg cm ( lb ft) kg cm ( lb ft) Adjusting spacer thickness 20 differences in thicknesses from to mm ( to in.) each differing by mm (0.001 in.) b. Using a spring balancer. Turning force: Unit: kg (lb) New bearing ( ) Re-used bearing ( ) SM Fig When the preload is correct, remove the flange and then install the new oil seal, flange and flange lock nut. Tighten the flange lock nut to the specified torque. Fig. 13 SM SM NOTE: Apply wheel bearing grease to the oil seal. Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. Special Tool: Socket wrench ( ) Tightening Torque: 6,000-8,000 kg cm ( lb ft) 13. Lock the flange lock nut by staking the lip into the pinion shaft slots. Fig. 14 SM10-467A 10 mm 1.5 mm SM NOTE: More than 1.5 mm (0.059 in.). Stake portion should be fitted in the groove thoroughly. Staking should be done without rift. Measure the bearing preload (see preceding page) and record it for TOTAL BEARING PRELOAD MEAS- UREMENT described in step 24 on page

27 Models FD and FE (SH14-1 Series) REAR AXLE Install the pinion assembly and the cylindrical roller bearing on the differential carrier. NOTE: At this point, align mark on the bearing cage and the other one on the differential carrier case. SM10-468A Fig Measure the drive pinion fitting height (conical distance) by using the pinion depth gauge. If the pinion fitting height is out of the specified value, adjust it with shim. Use a thinner shim to decrease and a thicker shim to increase the pinion fitting height. SM Nominal Pinion Fitting Height A : 27.0 mm (1.06 in.) Special Tool: Pinion depth gauge ( ) Fig. 16 D C B a. Pinion depth gauge setting method Set the pinion depth gauge onto the master bed, confirm the dimensions B, C, and D, and then set the dial gauge to 0. Dimension B = Nominal pinion fitting height A MASTER BED SM10-059B Height B C D 27.0 mm mm mm (1.06 in.) (1.36 in.) (0.92 in.) Fig. 17 A E b. Use method for the pinion depth gauge Set the pinion depth gauge as shown in the figure on the left, and read the value of the dial gauge. A : Measuring pinion-fitting height value E : Engraved value for gear toothing adjustment F : Adjusting shims F SM10-059A Fig. 18 Fig. 19 a SM10-470A Example: When the engraved value at the surface of the pinion gear a is -2 (-2 means -0.2 mm). Use shims to adjust so that the dial gauge reading becomes -0.2 mm. (A minus (-) reading of the dial gauge means that the tip of the dial gauge is pulled in.) Adjusting Shims Thickness: 0.3 mm (0.012 in.), 0.4 mm (0.016 in.), 0.45 mm (0.018 in.), 0.5 mm (0.020 in.).

28 10-28 REAR AXLE Models FD and FE (SH14-1 Series) 16. Tighten the differential carrier cage bolts to the specified torque. NOTE: Apply the sealing compound which is equivalent to THREE BOND No to the fitting faces of the carrier and the cage. Tightening Torque: 1,100-1,500 kg cm ( lb ft) Fig. 20 SM10-471B 17. Install and tighten the bearing lock washers with bolt and nut, and then stake the lock nut as shown. A Tightening Torque : kg cm (14-18 lb ft) A : Stake Fig. 21 SM SM Mount the differential case assembly on the differential carrier. Fig. 22 SM Install the adjusting nut and bearing cap on the differential carrier and tighten the cap temporarily with bolts. NOTE: Align the match marks of the cap and the differential carrier. Fig. 23 SM10-473A 20. Adjust the preload of the side bearing by using a special tool. 1) Tighten the adjusting nut on the back side of the ring gear fully, and then loosen it by 1/4 turn + 1 notch. 2) Do the same with the adjusting nut on the ring side. Special Tool: Adjuster tool ( ) Fig. 24 SM SM10-475

29 Models FD and FE (SH14-1 Series) REAR AXLE Strike the bearing cap with a copper hammer. SM10-476A Fig Measure the gear backlash at four points using a dial gauge with a magnet stand. If the measured value is out of specified value, adjust the gear backlash by turning the adjusting nuts, loosening one side one notch and tightening the other side one notch. SM Decrease Increase SM Assembly Standard: mm ( in.) Special Tool: Adjuster tool ( ) Fig. 26 SM10-72A 23. Inspection of gear tooth contact a. Satisfactory gear tooth contact a) The length of the tooth contact area in the direction of the tooth trace should be more than half the length of L, and the tooth contact area should be at the toe side. b) Tooth pressure should be distributed evenly over the contact area of the tooth. Fig. 27 NOTE: On new gears there is a blade-applying mark from lapping. Adjust the contact area to align with this mark. SM10-478A Fig. 28 A B b. Samples of unsatisfactory engagement. a) Toe and Flank contact. A: Replace (Toe contact) B: Adjust (Flank contact) SM10-072B Fig. 29

30 10-30 REAR AXLE Models FD and FE (SH14-1 Series) A B b) Heel and face contact. A: Replace (Heel contact) B: Adjust (Face contact) SM10-072C 24. Measure the total preload of the differential carrier bearings. NOTE: Total preload = Pinion bearing preload (Measured in step 13. on page 10-26) + Side bearing preload (Refer to tables below). If the preload is out of the specified limits, adjust it with the adjusting nuts of the side bearings. Tighten both side adjusting nuts evenly to increase SM10-479B and loosen them to decrease preload and re-inspect Fig. 31 the gear tooth contact. Special Tool: Adjuster tool ( ) 1. Using a torque wrench. Turning torque: Unit: kg cm (lb ft) Models FD FD, FE FD,FE FE Gear ratio New bearing ( ) ( ) ( ) ( ) Re-used bearing ( ) ( ) ( ) ( ) 2. Using a spring balancer. Fig. 32 SM10-480C Turning force: Models FD FD, FE FD, FE FE Unit: kg (lb) Gear ratio New bearing ( ) ( ) ( ) ( ) Re-used bearing ( ) ( ) ( ) ( )

31 Models FD and FE (SH14-1 Series) REAR AXLE Tighten the bearing cap bolts to the specified torque. Tightening Torque: 2,800-3,600 kg cm ( lb ft) Fig. 33 SM Install the lock plate. Tightening Torque: kg cm (14-18 lb ft) Fig. 34 SM10-482

32 10-32 REAR AXLE Models FD and FE (SH14-1 Series) 4 mm (0.16 in.) 3 mm (0.12 in.) 4 mm (0.16 in.) 3 mm (0.12 in.) SM Fig. 1 SM10-483B Fig. 2 INSTALLATION 1. INSTALLATION OF THE DIFFERENTIAL CARRIER 1. Install the differential carrier assembly. NOTE: 1. Apply the sealing compound to the face of the housing flange. a. The trace of the sealing compound should be continuous. b. Application should be approximately 3 mm (0.12 in.) width and 4 mm (0.16 in.) away from the edge. c. The sealing compound should be equivalent to THREE BOND#1215. NOTE: Be careful not to install the differential carrier upside down. Install the differential carrier so that the ring gear teeth face to the right side of the vehicle. Otherwise the vehicle will move backward while the transmission is shifted into forward gear. Tightening Torque: 1,100-1,500 kg cm ( lb ft) 2. INSTALL THE PROPELLER SHAFT TO DIFFERENTIAL CARRIER FLANGE. 1. Align the match marks on the flange and yoke. 2. When a propeller shaft yoke is secured by four bolts, bolt heads must face differential carrier. 3. Tighten the bolts to specified torque. Tightening Torque: kg cm (47-62 lb ft) Fig. 3 Model FD Model FE SM10-484B 3. INSTALL THE AXLE SHAFT. Tightening Torque: 870-1,100 kg cm (63-79 lb ft) Fig. 4 SM SM FILL THE DIFFERENTIAL WITH GEAR OIL. NOTE: Refer to the RECOMMENDED LUBRICANT LIST. Oil Capacity: Approx. 5.5L (5.81 U.S.Qt./4.84 lmp.qt.) Fig. 5 SM10-486

33 Models FF and SG (SH16-1 Series) REAR AXLE DIFFERENTIAL CARRIER (HINO SH16-1 series for models FF and SG) SM10-419A Model FF Model SG Flange lock nut 2. Flange yoke coupling 3. Dust deflector 4. Oil seal 5. Taper roller bearing 6. Bearing cage 7. Shim 8. Name plate 9. Spacer 10. Drive pinion 11. Cylindrical roller bearing 12. Retainer ring 13. Differential carrier case 14. Adjust nut 15. Differential case 16. Side gear thrust washer 17. Side gear 18. Pinion thrust washer 19. Pinion 20. Spider 21. Ring gear 22. Collar 23. Bearing cap 24. Lock plate SM Fig. 1

34 10-34 REAR AXLE Models FF and SG (SH16-1 Series) REMOVAL 1. REMOVAL OF DIFFERENTIAL CARRIER NOTE: Be sure to apply wheel stoppers in the front and rear of the front tires. Fig. 2 SM Disconnect the propeller shaft from the flange at the differential carrier. NOTE: Draw the aligning marks on the flange and yoke before disassembling. Fig. 3 SM Remove the filler and the drain plug to drain the gear oil from the axle housing. WARNING Do not work on differential carrier while it is still hot. This can result in personal injury. Fig. 4 SM Remove the bolts, and then pull the axle shafts out. Fig. 5 Fig. 6 SM SM10-424B 4. Use a jack to dismount the differential carrier assembly from the axle housing. WARNING When loosening the tightened bolts of the differential carrier, do not place yourself under the differential carrier. Be sure to apply a support before dismounting the differential carrier assembly.

35 Models FF and SG (SH16-1 Series) REAR AXLE DISASSEMBLY 1. DISASSEMBLY OF THE DIFFERENTIAL CARRIER 1. Mount the differential carrier assembly on a work stand. Fig. 7 SM Loosen the bolts, then remove the bearing cap from the differential carrier. NOTE: First apply match marks to the cap and carrier. Special Tool: Socket wrench ( ) Fig. 8 SM10-426A 3. Remove the differential case assembly from the carrier. Fig. 9 SM Remove the taper roller bearings at both ends of the differential case by using a puller. Fig. 10 SM NOTE: Do not change the combination of the assembled taper roller bearing and its race. Always replace the bearings with their original races. 5. Loosen the bolts and remove the ring gear from the differential case. NOTE: Be careful not to drop the ring gear from the differential case. Fig. 11 SM10-429

36 10-36 REAR AXLE Models FF and SG (SH16-1 Series) 6. Disassemble the differential case. NOTE: Be sure to check the aligning marks on the differential case before disassembly. Remove the bolts so that the case separates. SM Fig Loosen the bolts and remove the pinion assembly, and then remove the cylindrical roller bearing from the differential carrier. SM SM Fig Remove the lock nut using a special tool. Spread the staking of the nut completely with a chisel, then loosen the nut. NOTE: Insufficient spread of the staked parts will cause damage to the threads of the drive pinion when loosening the nut. Fig. 14 SM-434B SM Special Tool: Socket wrench ( ) 9. Separate the bearing cage and the pinion gear with a press. SM Fig Remove the taper roller bearing from the pinion gear using a puller. SM Fig. 16

37 Models FF and SG (SH16-1 Series) REAR AXLE Remove the retainer ring and then pull out the inner race for cylindrical roller bearing from the pinion gear using a puller. WARNING The retainer ring is spring steel and may pop out. Wear safety glasses to protect your eyes. Fig. 17 SM SM Remove the oil seal and the taper roller bearing outer races from the cage. NOTE: At the same time that the bearing is drawn out, the oil seal comes out. Be careful not to deform the oil seal. Fig. 18 SM INSPECTION 1. INSPECTION OF THE DIFFERENTIAL CARRIER 1. Check the flange coupling spline for wear and damage. Replace the coupling if damaged or worn. Fig. 19 SM Inspect the taper roller bearings, cylindrical roller bearing and races for burns or pitting. If such defects are found, replace it. Fig. 20 Fig. 21 SM SM SM10-445A 3. Inspect the drive pinion and ring gear teeth surfaces for wear, stripping or damage, and replace both parts as a set when defects are found. NOTE: The drive pinion and ring gear must be replaced as a set, not individually, because they are fitted to each other by lapping during manufacture. Replacement of only one part does not produce proper tooth contact, and gear strength drops excessively.

38 10-38 REAR AXLE Models FF and SG (SH16-1 Series) 4. Inspect the spider holes and surfaces of the differential case that come in contact with the thrust washers for wear or damage. Replace the case, if damaged or worn. Fig. 22 SM Inspect the pinion for wear or damage and check the amount of wear of the bore with a cylinder gauge. Fig. 23 Fig. 24 SM SM Inspect the spider for damage, and check the amount of wear by measuring its journals with a micrometer to determine the spider to pinion clearance. When the clearance is beyond the service limit, replace it. Standard clearance: Service limit: mm ( in.) 0.4 mm (0.016 in.) 7. Measure the thickness of the thrust washers on the pinion and side gears. Replace any washer worn beyond the limit. Standard Thickness: Side gear mm ( in.) Pinion gear mm ( in.) Fig. 25 SM10-449A SM Service Limit: Side gear Pinion gear 1.7 mm (0.067 in.) 1.5 mm (0.059 in.)

39 Models FF and SG (SH16-1 Series) REAR AXLE Measure the pinion backlash by using a dial gauge with a magnet base. When the backlash is beyond the service limit, replace the pinion gear and/or side gear. Fig. 26 SM Assembly standard: Service limit: mm ( in.) 0.90 mm ( in.) Put the side gear in the differential case so that the chamfering surface of the thrust washer is on the gear side. A A A 9. Measure the backlash of the side gear and pinion with the cogs of the pinion and side gear in the position shown in Fig. 27, D. A Pinion B Side gear B C B CORRECT B INCORRECT C Thrust washer D Correct E Incorrect Fig. 27 SM10-269B

40 10-40 REAR AXLE Models FF and SG (SH16-1 Series) Fig. 1 SM SM ASSEMBLY 1. ASSEMBLY AND ADJUSTMENT OF DIFFERENTIAL CARRIER 1. Assemble the differential case. NOTE: Align the aligning marks on cases. Tighten the bolts to the specified torque. Tightening Torque: 2,500-3,000 kg cm ( lb ft) 2. Install the ring gear to the differential case. NOTE: Apply the lock agent (Lock tight) which is equivalent to THREE BOND: 1360K on threads. Fig. 2 SM Tighten the bolts to the specified torque. Tightening Torque: 3,700-4,300 kg cm ( lb ft) Fig. 3 SM Install the taper roller bearing to both ends of the differential case using a press. Fig. 4 SM Install the cylindrical roller bearing inner race using a press and install the retainer ring on the end of the drive pinion. WARNING The retainer ring is spring steel and may pop out. Wear safety glasses when installing. Fig. 5 SM SM10-458

41 Models FF and SG (SH16-1 Series) REAR AXLE Using a press, install the inner taper roller bearing to the drive pinion. Fig. 6 SM Using a press, install the taper roller bearing outer races in the bearing cage. Fig. 7 SM SM Put the spacer to drive pinion. Fig. 8 SM10-582A 9. Using a press, assemble the bearing cage and taper roller bearing on the drive pinion. Fig. 9 SM Install the flange on the pinion shaft without oil seal, and then tighten the flange lock nut to the specified torque using a special tool. Special Tool: Socket wrench ( ) Tightening Torque: 6,000-8,000 kg cm ( lb ft) Fig. 10 SM10-464

42 10-42 REAR AXLE Models FF and SG (SH16-1 Series) Fig. 11 SM Measure the preload of the drive pinion bearings. If the preload is out of the specified limits, adjust it as following. Use a thinner spacer to increase and a thicker one to decrease preload. When new bearings, use the spacer of mm (0.686 in.) at first and measure the preload. This will be helpful to select the spacer for specified preload. Tighten the flange lock nut to the specified torque before re-checking a. Using a torque wrench. New bearing Re-used bearing Turning torque kg cm ( lb ft) kg cm ( lb ft) Adjusting spacer thickness 17 differences in thicknesses from to mm (0.680 to in.) each differing mm (0.001 in.) b. Using a spring balancer. Turning force: Unit: kg (lb) Models FF SG New bearing ( ) ( ) Re-used bearing ( ) ( ) SM Fig When the preload is correct, remove the flange and then install the new oil seal, flange and flange lock nut. Tighten the flange lock nut to the specified torque. NOTE: Apply wheel bearing grease to the oil seal lip. Wheel bearing grease: Refer to RECOMMENDED LUBRICANTS LIST. Special Tool: Socket wrench ( ) Tightening Torque: 6,000-8,000 kg cm ( lb ft) Fig. 13 SM SM Lock the flange lock nut by staking the lip into the pinion shaft slots. Fig. 14 SM10-467B 1.5 mm 10 mm SM NOTE: More than 1.5 mm (0.059 in.). Stake portion should be fitted in the groove thoroughly. Staking should be done without rift. Measure the bearing preload (see preceding page) and record it for TOTAL BEARING PRELOAD AD- JUSTMENT described in step 24 on page

43 Models FF and SG (SH16-1 Series) REAR AXLE Install the pinion assembly and the cylindrical roller bearing on the differential carrier. NOTE: At this point, align mark on the bearing cage and the other one on the differential carrier case. SM10-468A Fig Measure the drive pinion fitting height (conical distance) by using the pinion depth gauge. If the pinion fitting height is out of the specified value, adjust it with shim. Use a thinner shim to decrease and a thicker shim to increase the pinion fitting height. SM Nominal Pinion Fitting Height A : 33.0 mm (1.30 in.) Special Tool: Pinion depth gauge ( ) Fig. 16 D C B a. Pinion depth gauge setting method Set the pinion depth gauge onto the master bed, confirm the dimensions B, C, and D, and then set the dial gauge to 0. Dimension B = Nominal pinion fitting height A MASTER BED SM10-059B Height B C D 33.0 mm mm mm (1.30 in.) (1.167 in.) (1.12 in.) Fig. 17 A E b. Use method for the pinion depth gauge Set the pinion depth gauge as shown in the figure on the left, and read the value of the dial gauge. A : Measuring pinion-fitting height value E : Engraved value for gear toothing adjustment F : Adjusting shims F SM10-059A Fig. 18 a Example: If the engraved value at the surface of the pinion gear is 2 ( 2 means 0.2 mm). Individual variation from nominal a 33 mm 0.2 mm = 32.8 mm (1.30 in.) (0.008 in.) (1.29 in.) Fig. 19 SM10-470A Adjust the pinion fitting height to this value. Nominal pinion fitting height A Adjusting Shims Thickness 0.3 mm (0.012 in.) 0.4 mm (0.016 in.) 0.45 mm ( in.) 0.5 mm (0.020 in.)

44 10-44 REAR AXLE Models FF and SG (SH16-1 Series) 16. Tighten the differential carrier cage bolts to the specified torque. NOTE: Apply the sealing compound which is equivalent to THREE BOND No to the fitting faces of the carrier and the cage. Tightening Torque: 1,100-1,500 kg cm ( lb ft) Fig. 20 SM Install and tighten the bearing lock plates with bolts and nuts then lock the nuts by staking as shown. A Tightening Torque : kg cm (14-18 lb ft) Fig. 21 SM SM Mount the differential case assembly on the differential carrier. Fig. 22 SM Install the adjusting nut and bearing cap on the differential carrier and tighten the cap temporarily with bolts. NOTE: Align the match marks of the cap and the differential carrier. Fig. 23 SM10-473A 20. Adjust the preload of the side bearing by using a special tool. 1) Tighten the adjusting nut on the back side of the ring gear fully, and then loosen it by 1/4 turn + 1 notch. 2) Do the same with the adjusting nut on the ring side. Special Tool: Adjuster tool ( ) Fig. 24 SM SM10-475

45 Models FF and SG (SH16-1 Series) REAR AXLE Strike the bearing cap with a copper hammer. SM10-476A Fig Measure the gear backlash at four points using a dial gauge with a magnet stand. If the measured value is out of specified value, adjust the gear backlash by turning the adjusting nuts, loosening one side one notch and tightening the other side one notch. Fig. 26 SM Decrease Increase SM Assembly Standard: mm ( in.) (gear ratio: and 5.857) mm ( in.) (gear ratio: and 5.428) Special Tool: Adjuster tool ( ) Fig. 27 SM10-72A 23. Inspection of gear tooth contact a. Satisfactory gear tooth contact a) The length of the tooth contact area in the direction of the tooth trace should be more than half the length of L, and the tooth contact area should be at the toe side. b) Tooth pressure should be distributed evenly over the contact area of the tooth. NOTE: On new gears there is a blade-applying mark from lapping. Adjust the contact area to align with this mark. SM10-478A Fig. 28

46 10-46 REAR AXLE Models FF and SG (SH16-1 Series) A B b. Samples of unsatisfactory engagement. a) Toe and Flank contact. A: Replace (Toe contact) B: Adjust (Flank contact) Fig. 29 SM10-072B b) Heel and face contact. A B A: Replace (Heel contact) B: Adjust (Face contact) Fig. 30 Fig. 31 Turning torque: Models SM10-072C SM Unit: kg cm (lb ft) FF Gear ratio New bearing ( ) ( ) Re-used bearing ( ) ( ) 24. Measure the total preload of the differential carrier bearings. NOTE: Total preload = Pinion bearing preload (Measured at step 13. in page 10-42) + Side bearing preload (Refer to tables below). If the preload is out of the specified limits, adjust it with the adjusting nuts of the side bearings. Tighten both side adjusting nuts evenly to increase and loosen them to decrease preload and re-inspect the gear tooth contact. Special Tool: Adjuster tool ( ) 1. Using a torque wrench. Turning torque: Models SG1J SG Unit: kg cm (lb ft) Gear ratio New bearing ( ) ( ) ( ) ( ) Re-used bearing ( ) ( ) ( ) ( )

47 Models FF and SG (SH16-1 Series) REAR AXLE Using a spring balancer. Fig. 32 SM Turning force: Unit: kg (lb) Models FF Gear ratio New bearing ( ) ( ) Re-used bearing ( ) ( ) Turning force: Models SG1J SG Unit: kg (lb) Gear ratio New bearing ( ) ( ) ( ) ( ) Re-used bearing ( ) ( ) ( ) ( ) 25. Tighten the bearing cap bolts to the specified torque. Tightening Torque: 2,800-3,600 kg cm ( lb ft) Fig. 33 SM Install the lock plate. Tightening Torque: kg cm (14-18 lb ft) Fig. 34 SM10-482

48 10-48 REAR AXLE Models FF and SG (SH16-1 Series) Fig. 1 Fig. 2 Fig. 3 5 mm (0.20 in.) 3 mm (0.12 in.) SM SM SM INSTALLATION 1. INSTALLATION OF THE DIFFERENTIAL CARRIER 1. Install the differential carrier assembly. NOTE: 1. Apply the sealing compound to the face of the housing flange. a. The trace of the sealing compound should be continuous. b. Application should be approximately 3 mm (0.12 in.) width and 5 mm (0.20 in.) away from the edge. c. The sealing compound should be equivalent to THREE BOND#1215. NOTE: Be careful not to install the differential carrier upside down. Install the differential carrier so that the ring gear teeth face to the right side of the vehicle. Otherwise the vehicle will move backward while the transmission is shifted into forward gear. Tightening Torque: 1,100-1,500 kg cm ( lb ft) 2. INSTALL THE PROPELLER SHAFT TO DIFFERENTIAL CARRIER FLANGE. 1. Align the match marks on the flange and yoke. 2. When a propeller shaft yoke is secured by four bolts, bolt heads must face differential carrier. 3. Tighten the bolts to specified torque. Tightening Torque: For model FF kg cm (47-62 lb ft) For model SG 1,300-1,600 kg cm ( lb ft) 3. INSTALL THE AXLE SHAFT. Tightening Torque: 870-1,100 kg cm (63-79 lb ft) SM Fig FILL THE DIFFERENTIAL WITH GEAR OIL. NOTE: Refer to the RECOMMENDED LUBRICANT LIST. Oil Capacity: Approx L (10.57 U.S.Qt./8.80 lmp.qt.) SM Fig. 5