DIFFERENTIAL ASSEMBLY.

need for certain ring and pinion adjustments. Take

6-15. DIFFERENTIAL ASSEMBLY.

differential bearing cup from bore of axle housing, and

keep it with cone and rollers with which it was used.

a. Removal.

(3) Remove cotter pin and nut holding parking brake

(1) Remove entire mast assembly as a unit, as

drum to pinion (Figure 6-8). Remove drum and key from

follows:

pinion. Remove screws and washers, and take off seal

and retainer, parking brake bracket with brake assembly

(a) Attach a chain hoist to mast assembly (or use

attached, and gasket.

Remove cover screws and

the forks of another lift truck), and relieve the weight of

washers, and take off cover with pinion and spacer

the assembly. on its supporting parts. Arrange to brace

gaskets. Press pinion from cover. Measure gaskets

the assembly against tipping as disconnections are

before discarding, as in (2) above.

made. The forks are to be fully lowered at this time.

(4) Take remainder of differential assembly from

(b) Disconnect hydraulic hose from lift cylinder

housing. Pull differential side bearings from case halves,

and cap hose and cylinder to exclude dirt.

if they are to be replaced. Remove bearings from pinion,

if they are to be replaced.

hoses from the tilt cylinder. Tag hoses for position and

(5) Remove screws holding differential case halves

ease of reassembly.

together and separate case halves. Remove spider,

gears, spring washers and thrust washers.

(d) Remove four screws and washers, releasing

two plates. One plate is located at the forward end of the

(6) If necessary to replace ring gear, center punch

cylinder, one upright assembly, and the other on frame

each rivet, drill a pilot hole through, and drill off head of

assembly at rear of cylinder.

rivet from bevel end. Punch out rivet.

(e) Remove plates. Grasp cylinder firmly and

NOTE

pull shafts from their position. Lift tilt cylinder assembly

from vehicle.

Ring gear and pinion must both be

replaced as a set, if one is defective.

(f) Remove capscrews, washers and angle

brackets which secure outer uprights to bearing bracket

c. Inspection.

on frame and lift mast assembly from truck. Disconnect

brake lines.

(1) Inspect gears for wear or damage.

(2) Drain lubricant from axle. Support front end of

(2) Inspect for pitted, scored, or worn thrust faces of

truck so axle can be rolled free, and remove screws,

face halves, thrust washers, spider trunnions.

washers and bearing caps, holding axle to frame.

Disconnect propeller shaft from parking brake drum-y

(3) Inspect spider trunnions also for looseness in

removing two screws from each top and bottom needle

differential case bores. Check for free rotation of bevel

bearings. Raise truck front and roll axle free.

gears on spider trunnions.

CAUTION

Assembly.

Assembly of the differential is

essentially the reverse of the disassembly procedure in

Support axle, when truck weight is relieved,

b. above, for sequence in which parts are installed.

to prevent sudden turning of the axle due to

However, in the course of assembly, various checks and

unbalance, which could cause injury to

adjustments are to be made. Assemble by reversing the

personnel.

procedure in b. as appropriate, and incorporate the

checks and adjustments in e. below in the assembly

b. Disassembly.

procedure.

NOTE

(1) Remove nuts, washers, and tapered bushings

At assembly, use press where necessary.

from studs (Figure 6-1) attaching axle and differential

Install all new seals and gaskets. Replace

housings. Tap parts with a soft mallet, if necessary, to

ring gear and pinion as a set, if either is to be

free bushings from grip on studs, for disassembly. Studs

replaced. Replace thrust washers only in

may be left in place, if not to be serviced.

complete sets.

(2) Remove gaskets from studs and measure the

e. Assembly checks and adjustments. Three basic

thickness removed from each side. If no new parts are

adjustments are to be made when the differential has

needed in the differential, the same thickness of new

been reassembled after replacement of parts. These are

gaskets can be installed at assembly. This will eliminate

the