chapter 10 rear axle - tgidirect.com service manual...chapter 10 rear axle models fd, fe, ... 19....

Models FD, FE, FF and SG REAR AXLE 10-1

10-108E-07

CHAPTER 10REAR AXLEModels FD, FE, FF and SG

TROUBLESHOOTING...............................................................10 - 2

SPECIAL TOOL .........................................................................10 - 3

WHEEL HUB AND RELATED PARTS

DISASSEMBLY ................................................................10 - 7

INSPECTION ....................................................................10 - 9

ASSEMBLY AND ADJUSTMENT ....................................10 - 12

DIFFERENTIAL CARRIER (For Models FD and FE) ..............10 - 17HINO SH14-1 series

Single speedSingle reduction

DIFFERENTIAL CARRIER (For Models FF and SG) ..............10 - 33HINO SH16-1 series

Single speedSingle reduction

10

1 INDEX

Models FD, FE, FF and SG10-2 REAR AXLE

1 page 1

Abnormal noise Bearing system

● Worn or damaged pinion bearings ................ Replace bearings

● Worn or damaged differentialside bearings ................................................. Replace bearings

● Loose pinion bearings ................................... Adjust bearing preload

● Loose differential side bearings .................... Adjust bearing preload

Gear system

● Inadequate backlash on ring gearand 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 gearsand pinions .................................................... Replace

● Loose ring gear tightening bolts .................... Tighten bolts

● Inadequate tooth contact of ring gear andpinion 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 9PROPELLER SHAFT

TROUBLESHOOTING

Symptom Possible cause Remedy


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SPECIAL TOOL

Prior to starting a rear axle overhaul, it is necessary to have those special tools.

Illustration Tool No. Tool name

WHEEL HUB PULLER

HUB NUT WRENCH

HUB BEARING PULLER

09665 - 1040 ADJUSTER TOOL

09839 - 4601 SOCKET WRENCH

09849 - 1601 HANDLE09849 - 2001

Model

FD 09650 - 2050

FEFF 09650 - 1292SG

FEFF 09603 - 1210SG

09650 - 2090

FD 09839 - 9401


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Illustration Tool No. Tool name

09640 - 1151 PINION DEPTH GAUGE

09603 - 1150 SOCKET WRENCH


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11. Hub bolt12. Wheel nut inner13. Wheel nut outer14. Air breather15. Plug16. Washer17. Rear axle housing assembly18. Differential carrier assembly19. ABS sensor ring

WHEEL HUB AND RELATED PARTS

NOTE: ● The illustrations and the text are based on FE and FF vehicles. In the case of FD andSG vehicles, there are several differences in the number of hub bolts and the shapesof the components. However, the operation procedures are the same except where speci-fied.

● From the 1999 model year, all FD, FE, FF and SG vehicles are equipped with ABS (Anti-lock Brake System). As a result, the operation procedures for taking off and putting onthe wheel hubs are very different. Please read this chapter carefully before working onthese vehicles.

Fig. 1

SM10-630

12

3

910

4

35

67

18

1112

13

14

1516

17

1615

18

Model FD

1. Oil seal2. Collar3. Taper roller bearing4. Hub5. Lock washer6. Lock nut7. Lock plate8. Axle shaft9. Hub bolt nut

10. Oil deflector

19


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Fig. 2

Models FE, FF and SG

12

19

1. Oil seal2. Collar3. Taper roller bearing4. Hub5. Lock washer6. Lock nut7. Lock plate8. Axle shaft9. Hub bolt nut

10. Oil deflector

11. Hub bolt12. Wheel nut inner13. Wheel nut outer14. Air breather15. Plug16. Washer17. Rear axle housing assembly18. Differential carrier assembly19. ABS sensor ring

81

36

57

4

32

1

109

18

1516

17

1411

1516 13

SM10-631


1 page 1

MODELS FE, FF AND SGMODEL FD

SM10-548

DISASSEMBLY1. REMOVAL OF REAR WHEELS

NOTE: Refer to CHAPTER 16, WHEEL AND TIRE.

2. DISASSEMBLY OF WHEEL HUB AND RELATED PARTS1. Remove the brake drum set bolts, and then remove

the drum from the wheel hub.

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 weighs40 kg (88 lb), and for model SG weighs 44 kg (97lb). Be careful not to drop them.

● To assure safety, do this operation with morethan two persons.

2. Loosen and remove the bolts, and then remove theaxle shaft.

3. Remove the oil seal, and then loosen the bolts andremove the lock plate.

4. Remove the taper roller bearing lock nut using aspecial tool, and then remove the lock washer.

Special Tool:For model FD:

Hub nut wrench (09839 - 9401)For models FE, FF and SG:

Hub nut wrench (09603 - 1210)Handle (09849 - 2001)

SM10-495

SM10-496

SM10-497

SM10-498

Fig. 4

Fig. 3

Fig. 2

Fig. 1


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Model SG 7. Remove the ABS wheel sensor.After removing the harness connector for the ABSwheel sensor and the cable clip, remove the ABSwheel sensor with its holder.

NOTE: Subjecting the wheel sensor to a strongshock can cause internal damage. Do notstrike the wheel sensor with a hammer orbump it against other components.

8. Remove the wheel brake.NOTE: Refer to CHAPTER 13, SERVICE BRAKE.

6. Using a special tool, remove the inner taper rollerbearing with oil seal collar from the axle housing.

Special Tool: Hub bearing puller (09650 - 2090)Handle (09849 - 2001) or (09849 - 1601)

5. Using a special tool, remove the wheel hub with theouter taper roller bearing from the axle housing.

Special Tool: Wheel hub puller(09650 - 2050) for model FD(09650 - 1292) for model FE, FF and SG

WARNING● The wheel hub assembly is heavy. The rear wheel

hub assembly for model FD weighs 20 kg (44lb), for models FE, FF and SG weighs 30 kg (66Ib). Be careful not to drop it.


Fig. 5

Fig. 6

Models FD, FE and FF

Models FD,FE and FF

Fig. 7

SM10-500 SM10-407

Model SG

SM10-349

SM10-499


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INSPECTION1. INSPECTION OF THE WHEEL HUB

1. Inspect the taper roller bearing with race for burnsor pitting, and replace it if such defects are found.

2. Inspect the taper roller bearing race for burns, cracks,or brinelling on the raceways, and replace it if suchdefects are seen.

NOTE: The bearing and the bearing race must bereplaced as a set.

3. Replacement of taper roller bearing race.a. Remove the taper roller bearing race from the hub

bore.

b. Install the new taper roller bearing race in the hubbore.

4. Inspect the hub bolts.Replace the bolts if the threads of the bolts are wornor damaged.

SM10-501

SM10-502

SM10-503

SM10-504A

SM10-505

Fig. 5

Fig. 4

Fig. 3

Fig. 2

Fig. 1


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A

5. Replacement of hub bolta. Loosen the hub bolt nuts and remove the hub bolts

from the wheel hub.

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.

Tightening Torque : 4,000 - 4,800 kg·cm(290 - 347 lb·ft)

A : Stake

NOTE: Stake the lock nuts at the two points aftertightened to the specified torque.

6. Inspect the oil seal collar for wear.If the collar is excessively worn at the point of con-tact with the lip of the oil seal, replace it.

7. Inspect the axle shaft spline for wear or damage.If the spline is excessively worn or damaged, replacethe shaft.

SM10-506

SM10-508SM10-507

SM10-509

SM10-510

Fig. 9

Fig. 8

Fig. 7

Fig. 6

Marks on the end Color

RIGHT R gold

LEFT L silver


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Fig. 25

Fig. 12

a. Removal of the sensor ringUniformly tap on the periphery of the sensor ringusing 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.

b. Installation of the sensor ring1) 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 procedureto be carried out smoothly. Never use a gasburner. Doing so can cause the sensor ringto be deformed.

8. Clamp bushing1. 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

8. Inspect the axle tube.If the tube is abnormally worn or damaged at the pointof contact with the lip of the oil seal, replace the axlehousing.

9. 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.

2) After pushing it in, check the axle direction wobbleof the sensor ring.

Standard range: Under 0.2 mm (0.0079 in.)

Fig. 10

SM10-511

ADHESION

SENSOR RINGPRESS BOARD

GAP

Fig. 13


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Fig. 5

SM10-500

Models FD,FE and FF

ASSEMBLY AND ADJUSTMENT1. 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 sensoris not proceeded.

For models FD, FE and FFTightening Torque: 1,500 - 2,000 kg·cm

(109 - 144 lb·ft)For model SGTightening Torque: 1,700 - 2,300 kg·cm

(123 - 166 lb·ft)

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

2. Apply wheel bearing grease to the taper roller bear-ing.

Wheel bearing grease:Refer to RECOMMENDED LUBRICANTS LIST.

5. Install the ABS wheel sensor.After applying a thin film of chassis grease to thewheel sensor body, press the wheel sensor into theclamp bushing (holder) until the tip of the wheel sen-sor and the side surface of the holder become flatand install the holder on the base portion of the axletube and tighten with the specified torque.

Tightening torque: 351 - 527 kg.cm (25 - 38 lb·ft)

4. Install the oil seal collar and inner taper roller bear-ing on the axle housing.

WARNINGWhen hammering, a metal tip may fly off on impact.Wear safety glasses to protect your eyes.

NOTE: This procedure must be performed after theABS wheel sensor has been removed.

For model SG

SM10-407

SM10-512

SM10-514

SM10-513

Model SG

For modelsFD, FE and FF

Fig. 1

Fig. 2

Fig. 3

Fig. 4


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SM10-516

MODEL FD

SM10-548

NOTE: ● The bolts should be tightened by hand.Never use an impact wrench.

● In this condition, the wheel sensor is stilltemporarily installed and should be fi-nally installed after the pre-load adjust-ment of the wheel hub assembly.

6. Install the wheel hub and taper roller bearing (outer)on the axle housing.

WARNING● Wheel hub assembly is heavy. The rear wheel

hub assembly for model FD weighs 20 kg (44lb), for model FE, FF and SG weighs 30 kg (66Ib). Be careful not to drop it.


NOTE: ● Before installing the wheel assembly,clean the surface of the ABS sensor ring.

● The installation of the wheel assemblyshould be done calmly and straight in or-der not to apply an impact to the ABSwheel sensor.

● The installation of the outer wheel bear-ing should be done calmly using the bear-ing lock nuts. Never hammer the bearingin as is customary.

7. Install the lock washer and lock nut.a. Tighten the nut to the specified torque using a spe-

cial tool while turning the wheel hub.

Special Tool:For model FD:

Hub nut wrench (09839 - 9401)For models FE, FF and SG:

Hub nut wrench (09603 - 1210)Tightening Torque: 5,000 - 6,000 kg·cm

(362 - 433 lb·ft)

b. Loosen the lock nut by 1/4 to 1/3 turn using a spe-cial tool.

Fig. 6

Fig. 7

Fig. 8

SM10-498

MODELS FE, FF AND SG


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Fig. 9

8. Install the oil seal on the wheel hub.

SM10-519

d. Measure the wheel bearing preload.Adjust the preload with the lock nut, if it exceeds oris less than specifications.

[For model FD]Standard preload: 40 - 60 kg.cm (2.9 - 4.3 lb·ft)(Turning torque)Spring balance value: 3.6 - 5.4 kg (8.0 - 11.9 lb)(Turning force)

[For models FE, FF and SG]Standard preload: 50 - 90 kg.cm (3.7 - 6.5 lb·ft)(Turning torque)Spring balance value: 3.5 - 6.3 kg (7.8 - 13.8 lb)(Turning force)

c. Pull the wheel hub using the special tool in order tofit the bearing.

NOTE: Since this procedure is performed in order notto apply an impact to the ABS wheel sensor,never hammer the bearing as is customary.

Special tool: Wheel hub puller (09650-2050) for model FD (09650-1292) for models FE, FF and SG

e. Apply the lock plate and align it with the small screwhole of the nut. If the hole does not align, turn overthe plate. If alignment is still unattainable, turn thelock nut further within the limits of hub turning torque.

Tightening Torque:For model FD:

85 - 110 kg·cm (6.2 - 7.9 lb·ft)For models FE, FF and SG:

190 - 260 kg·cm (14 - 18 lb·ft)SM10-518

SM10-536

SM10-499

Fig. 10

Fig. 11

Fig. 12


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Models FD, FE and FF

Model SG

Fig. 14

Fig. 15

Fig. 16

HUB

10. Positioning the ABS wheel sensora. Temporarily remove the brake lining of the wheel sen-

sor installation side.The drum cover must be removed on SG vehicles.

b. Fully depress the wheel sensor until it makes con-tact with the wheel sensor ring.

c. Restore the brake lining.On SG vehicles, install the drum cover.

NOTE: Refer to Chapter 13, SERVICE BRAKE.

9. Install the axle shaft in the wheel hub and tightenthe set bolts to the specified torque.

Tightening Torque: 870 - 1,100 kg·cm (63 - 79 lb·ft)

SM10-521

Fig. 13

WHEELSENSORMAKE CONTACT

CLAMPBUSHING

SENSORRING


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2. INSTALLATION OF THE REAR WHEELSNOTE: Refer to CHAPTER 16, WHEEL AND TIRE.

3. FOR MODELS FD, FE AND FFBRAKE SYSTEM AIR BLEEDING AND BRAKE SHOECLEARANCE 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 sec-

tion FINAL CHECK AND ADJUSTMENT in CHAP-TER 13, SERVICE BRAKE.

b. Adjust the brake shoe clearance according to sec-tion INSPECTION AND ADJUSTMENT in CHAPTER13, SERVICE BRAKE.

4. FOR MODEL SGBRAKE CHAMBER ROD STROKEOn completion of the real axle reassembly, adjust the brakechamber rod stroke according to the section INSPECTIONAND ADJUSTMENT in CHAPTER 13, SERVICE BRAKE.

11. Install the brake drum on the wheel hub and tightenthe drum set bolts.

Tightening Torque: 200 - 400 kg·cm (15 - 28 lb·ft)NOTE: Before installing the drum, fully retract the

brake adjuster so that the outer diameter ofthe lining becomes minimum.

WARNING● The drums are heavy. The rear drum for model

FD weighs 30 kg (66 lb), for models FE and FFweighs 40 kg (88 lb), and for model SG it weighs44 kg (97 lb).


SM10-520

Fig. 17

Models FD and FE (SH14-1 Series) REAR AXLE 10-17

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DIFFERENTIAL CARRIER(HINO SH14-1 series for models FD and FE)

1. Flange lock nut2. Flange yoke coupling3. Dust deflector4. Oil seal5. Taper roller bearing6. Bearing cage7. Shim8. Name plate9. Spacer

10. Drive pinion11. Cylindrical roller bearing12. Retainer ring

13. Differential carrier case14. Adjust nut15. Differential case16. Side gear thrust washer17. Side gear18. Pinion thrust washer19. Pinion20. Spider21. Ring gear22. Collar23. Bearing cap24. Lock plate

2

SM10-419A

Fig. 1

34

5

67

145

15

16 17 1819

20

2223

24

15

145

21

13

8

1211

10

59

1

Models FD and FE (SH14-1 Series)10-18 REAR AXLE

1 page 1

REMOVAL1. REMOVAL OF DIFFERENTIAL CARRIER

NOTE: Be sure to apply wheel stoppers in the frontand rear of the front tires.

Fig. 2

SM10-488

1. Disconnect the propeller shaft from the flange at thedifferential carrier.

NOTE: Draw the aligning marks on the flange andyoke before disassembling.

Fig. 3

SM10-421B

2. Remove the filler and the drain plug to drain the gearoil from the axle housing.

WARNINGDo not work on differential carrier while it is stillhot.This can result in personal injury.

Fig. 4

SM10-422

3. Remove the bolts, and then pull the axle shafts out.

Fig. 5

SM10-489A

4. Use a jack to dismount the differential carrier assem-bly from the axle housing.

WARNING● When loosening the tightening bolts of the dif-

ferential carrier, do not place yourself under thedifferential carrier.

● Be sure to apply a support before dismountingthe differential carrier assembly.

Fig. 6

SM10-424C

SM10-489

Model FD Model FE


1 page 1

DISASSEMBLY1. DISASSEMBLY OF THE DIFFERENTIAL CARRIER

1. Mount the differential carrier assembly on a workstand.

Fig. 7

2. Loosen the bolts, then remove the bearing cap fromthe differential carrier.

NOTE: First apply match marks to the cap and car-rier.

Special Tool: Socket wrench (09603-1150)

Fig. 8

SM10-426A

3. Remove the differential case assembly from the car-rier.

Fig. 9

SM10-427

4. Remove the taper roller bearings at both ends of thedifferential case by using a puller.

NOTE: ● Do not change the combination of theassembled taper roller bearing and itsrace.

● Always replace the bearings with theiroriginal races.

Fig. 10

SM10-428

5. Loosen the bolts and remove the ring gear from thedifferential case.

NOTE: Be careful not to drop the ring gear from thedifferential case.

Fig. 11

SM10-429

SM10-425B


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6. Disassemble the differential case.

NOTE: Be sure to check the aligning marks on thedifferential case before disassembly. Re-move the bolts so that the case separates.

7. Loosen the bolts and remove the pinion assembly,and then remove the cylindrical roller bearing fromthe differential carrier.

Fig. 13

SM10-433

8. 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 willcause damage to the threads of the drive pin-ion when loosening the nut.

Special Tool: Socket wrench (09839 - 4601)

Fig. 14

SM10-434A

10. Remove the taper roller bearing from the pinion gearusing a puller.

Fig. 16

SM10-437

SM10-435A

Fig. 12

SM10-430

SM10-432B

9. Separate the bearing cage and the pinion gear witha press.

Fig. 15

SM10-436


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11. Remove the retainer ring and then pull out the innerrace for cylindrical roller bearing from the pinion gearusing a puller.

WARNINGThe retainer ring is spring steel and may pop out.Wear safety glasses to protect your eyes.

12. Remove the oil seal and the taper roller bearing outerraces from the cage.

NOTE: At the same time that the bearing is drawnout, the oil seal comes out. Be careful not todeform the oil seal.

Fig. 18

SM10-440

INSPECTION1. INSPECTION OF THE DIFFERENTIAL CARRIER

1. Check the flange coupling spline for wear and dam-age.Replace the coupling if damaged or worn.

Fig. 19

SM10-442A

2. Inspect the taper roller bearings, cylindrical rollerbearing and races for burns or pitting.If such defects are found, replace it.

Fig. 20

SM10-444

3. Inspect the drive pinion and ring gear teeth surfacesfor wear, stripping or damage, and replace both partsas a set when defects are found.

NOTE: The drive pinion and ring gear must be re-placed as a set, not individually, because theyare fitted to each other by lapping duringmanufacture.Replacement of only one part does not pro-duce proper tooth contact, and gear strengthdrops excessively.Fig. 21

SM10-445A

Fig. 17

SM10-439SM10-438

SM10-443


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4. Inspect the spider holes and surfaces of the differ-ential case that come in contact with the thrust wash-ers for wear or damage. Replace the case, if dam-aged or worn.

Fig. 22

SM10-446

5. Inspect the pinion for wear or damage and check theamount of wear of the bore with a cylinder gauge.

Fig. 23

SM10-447

Fig. 24

SM10-448

7. Measure the thickness of the thrust washers on thepinion and side gears. Replace any washer wornbeyond the limit.

Standard Thickness:Side gear 1.5 - 1.7 mm (0.060 - 0.066 in.)Pinion gear 1.45 - 1.75 mm (0.057 - 0.068 in.)

Service Limit:Side gear 1.3 mm (0.051 in.)Pinion gear 1.3 mm (0.051 in.)

Fig. 25

SM10-450

6. Inspect the spider for damage, and check the amountof wear by measuring its journals with a micrometerto determine the spider to pinion clearance.When the clearance is beyond the service limit, re-place it.

Standard clearance: 0.140 - 0.261 mm(0.0056 - 0.0102 in.)

Service limit: 0.4 mm (0.016 in.)

SM10-449A


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8. Measure the pinion backlash by using a dial gaugewith a magnet base.When the backlash is beyond the service limit, re-place the pinion gear and/or side gear.

Assembly standard: 0.20 - 0.60 mm(0.0079 - 0.0236 in.)


Put the side gear in the differential case so that thechamfering surface of the thrust washer is on thegear side.

Fig. 26

SM10-451

Fig. 27

SM10-269B

A

B

C

A

B

CORRECT

A

B

INCORRECT

A Pinion B Side gear

C Thrust washer D Correct

E Incorrect

9. Measure the backlash of the side gear and pinionwith the cogs of the pinion and side gear in the posi-tion shown in Fig. 27, D.


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2. Install the ring gear to the differential case.

NOTE: Apply the lock agent (Lock tight) which isequivalent to THREE BOND: 1360K onthreads.

Fig. 2

SM10-454

Fig. 3

SM10-455

Fig. 4

SM10-456

Fig. 5

SM10-458

3. Tighten the bolts to the specified torque.

Tightening Torque: 3,700 - 4,300 kg·cm(268 - 311 lb·ft)

5. Install the cylindrical roller bearing inner race usinga press and install the retainer ring on the end of thedrive pinion.


4. Install the taper roller bearing to both ends of the dif-ferential case using a press.

SM10-457

ASSEMBLY1. ASSEMBLY AND ADJUSTMENT OF DIFFERENTIAL

CARRIER1. 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 onthreads.

Tightening Torque: 1,700 - 2,200 kg·cm (123 -159 lb·ft)Fig. 1

SM10-453SM10-452


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7. Using a press, install the taper roller bearing outerraces in the bearing cage.

8. Put the spacer to drive pinion.

Fig. 8

Fig. 9

SM10-463

SM10-582A

Fig. 7

SM10-460 SM10-461

9. Using a press, assemble the bearing cage and ta-per roller bearing on the drive pinion.

10. Install the flange on the pinion shaft without oil seal,and then tighten the flange lock nut to the specifiedtorque using a special tool.

Special Tool: Socket wrench (09839 - 4601)Tightening Torque: 6,000 - 8,000 kg·cm

(434 - 578 lb·ft)

Fig. 10

SM10-464A

6. Using a press, install the inner taper roller bearingto the drive pinion.

Fig. 6

SM10-459


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New bearing Re-used bearing

Turning torque 20 - 25 kg·cm (1.5 - 1.8 lb·ft) 15 - 20 kg·cm (1.1 - 1.4 lb·ft)

Adjusting spacer thickness 20 differences in thicknesses from 13.900 to 14.375 mm (0.5473 to 0.5659 in.)each differing by 0.025 mm (0.001 in.)

b. Using a spring balancer.

Turning force: Unit: kg (lb)

New bearing 3.2 - 4.0 (7.1 - 8.8)

Re-used bearing 2.4 - 3.2 (5.3 - 7.0)

Fig. 12

SM10-116

12. When the preload is correct, remove the flange andthen install the new oil seal, flange and flange locknut.Tighten the flange lock nut to the specified torque.

NOTE: Apply wheel bearing grease to the oil seal.Wheel bearing grease:

Refer to RECOMMENDED LUBRICANTS LIST.Special Tool: Socket wrench (09839 - 4601)Tightening Torque: 6,000 - 8,000 kg·cm (434 - 578 lb·ft)

Fig. 13

SM10-466

13. Lock the flange lock nut by staking the lip into thepinion shaft slots.

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 10-30.Fig. 14

SM10-494

SM10-487

1.5 mm

SM10-467A

10 mm

11. Measure the preload of the drive pinion bearings.If the preload is out of the specified limits, adjust itas follows.Use a thinner spacer to increase and a thicker oneto decrease preload. When new bearings, use thespacer of 14.175 mm (0.558 in.) at first and meas-ure the preload. This will be helpful to select thespacer for specified preload.Tighten the flange lock nut to the specified torquebefore re-checking.

a. Using a torque wrench.Fig. 11

SM10-465A


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14. Install the pinion assembly and the cylindrical rollerbearing on the differential carrier.

NOTE: At this point, align mark on the bearing cageand the other one on the differential carriercase.

Fig. 15

15. Measure the drive pinion fitting height (conical dis-tance) 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 shimto increase the pinion fitting height.

Nominal Pinion Fitting Height “A”: 27.0 mm (1.06 in.)Special Tool: Pinion depth gauge (09640-1151)

Fig. 16

SM10-469

a. Pinion depth gauge setting methodSet the pinion depth gauge onto the master bed,confirm the dimensions B, C, and D, and then setthe dial gauge to “0”.Dimension B = Nominal pinion fitting height “A”

Fig. 17

SM10-059B

B C D

Height27.0 mm 34.65 mm 23.35 mm(1.06 in.) (1.36 in.) (0.92 in.)

b. Use method for the pinion depth gaugeSet the pinion depth gauge as shown in the figureon the left, and read the value of the dial gauge.A : Measuring pinion-fitting height valueE : Engraved value for gear toothing adjustmentF : Adjusting shims

Fig. 18

SM10-059A

Example: When the engraved value at the surface of thepinion gear “a” is -2 (-2 means -0.2 mm).Use shims to adjust so that the dial gaugereading becomes -0.2 mm.(A minus (-) reading of the dial gauge meansthat 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.).

Fig. 19

SM10-470A

MASTER BED

E

F

DC B

SM10-468A

A

“a”


1 page 1

16. Tighten the differential carrier cage bolts to the speci-fied torque.

NOTE: Apply the sealing compound which is equiva-lent to THREE BOND No. 1215 to the fittingfaces of the carrier and the cage.

Tightening Torque: 1,100 - 1,500 kg·cm (80 - 108 lb·ft)

17. Install and tighten the bearing lock washers with boltand nut, and then stake the lock nut as shown.

Tightening Torque : 190 - 260 kg·cm (14 - 18 lb·ft)A : Stake

18. Mount the differential case assembly on the differ-ential carrier.

19. Install the adjusting nut and bearing cap on the dif-ferential carrier and tighten the cap temporarily withbolts.

NOTE: Align the match marks of the cap and the dif-ferential carrier.

Fig. 20

Fig. 21

Fig. 22

Fig. 23

SM10-471B

SM10-493

SM10-427

SM10-473A

SM10-472

20. Adjust the preload of the side bearing by using aspecial tool.

1) Tighten the adjusting nut on the back side of the ringgear 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 (09665 - 1040)

Fig. 24

SM10-475SM10-474

A


1 page 1

21. Strike the bearing cap with a copper hammer.

Fig. 25

SM10-476A

22. Measure the gear backlash at four points using a dialgauge with a magnet stand. If the measured valueis out of specified value, adjust the gear backlash byturning the adjusting nuts, loosening one side onenotch and tightening the other side one notch.

Assembly Standard: 0.25 - 0.33 mm (0.0099 - 0.0129 in.)Special Tool: Adjuster tool (09665 - 1040)

Fig. 26

SM10-540

23. Inspection of gear tooth contacta. Satisfactory gear tooth contacta) The length of the tooth contact area in the direction

of the tooth trace should be more than half the lengthof L, and the tooth contact area should be at the toeside.

b) Tooth pressure should be distributed evenly over thecontact area of the tooth.

SM10-477

Fig. 27

SM10-72A

NOTE: On new gears there is a blade-applying markfrom lapping. Adjust the contact area to alignwith this mark.

Fig. 28

SM10-478A

b. Samples of unsatisfactory engagement.a) Toe and Flank contact.

A: Replace (Toe contact)

B: Adjust (Flank contact)

A B

Fig. 29

SM10-072B

DecreaseIncrease


1 page 1

SM10-072C

Fig. 31

SM10-479B

Fig. 32

SM10-480C

A B

b) Heel and face contact.

A: Replace (Heel contact)

B: Adjust (Face contact)

24. Measure the total preload of the differential carrierbearings.

NOTE: Total preload = Pinion bearing preload (Meas-ured in step 13. on page 10 - 26) + Side bear-ing preload (Refer to tables below).

If the preload is out of the specified limits, adjust itwith the adjusting nuts of the side bearings.Tighten both side adjusting nuts evenly to increaseand loosen them to decrease preload and re-inspectthe gear tooth contact.

Special Tool: Adjuster tool (09665 - 1040)1. Using a torque wrench.

Turning torque: Unit: kg·cm (lb·ft)Models FD FD, FE FD,FE FE

Gear ratio 4.333 5.125 5.428 5.857

New 4.7 - 5.7 3.9 - 4.8 3.7 - 4.6 3.5 - 4.2bearing (0.34 - 0.41) (0.29 - 0.35) (0.27 - 0.33) (0.25 - 0.30)

Re-used 3.5 - 4.6 3.0 - 3.9 2.8 - 3.6 2.6 - 3.2bearing (0.25 - 0.33) (0.22 - 0.28) (0.20 - 0.26) (0.18 - 0.23)

2. Using a spring balancer.

Turning force: Unit: kg (lb)Models FD FD, FE FD, FE FE

Gear ratio 4.333 5.125 5.428 5.857

New 0.74 - 0.92 0.63 - 0.78 0.59 - 0.73 0.55 - 0.68bearing (1.63 - 2.03) (1.38 - 1.72) (1.30 - 1.62) (1.21 - 1.50)

Re-used 0.56 - 0.73 0.47 - 0.62 0.45 - 0.59 0.42 - 0.54bearing (1.23 - 1.62) (1.04 - 1.37) (0.98 - 1.30) (0.91 - 1.20)


1 page 1

26. Install the lock plate.

Tightening Torque: 190 - 260 kg·cm (14 - 18 lb·ft)

Fig. 34

SM10-482

25. Tighten the bearing cap bolts to the specified torque.


Fig. 33

SM10-481


1 page 1

Fig. 5

SM10-486

3. INSTALL THE AXLE SHAFT.


Fig. 4

Model FD Model FE

SM10-490 SM10-485

INSTALLATION1. 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 equiva-lent to THREE BOND#1215.

NOTE: Be careful not to install the differential car-rier upside down. Install the differential car-rier so that the ring gear teeth face to the rightside of the vehicle. Otherwise the vehicle willmove backward while the transmission isshifted into forward gear.


4 mm (0.16 in.)

3 mm (0.12 in.)

4 mm (0.16 in.) 3 mm (0.12 in.)

Fig. 1

SM10-131

Fig. 2

SM10-483B

2. INSTALL THE PROPELLER SHAFT TO DIFFERENTIALCARRIER 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: 650 - 870 kg·cm (47 - 62 lb·ft)

Fig. 3

SM10-484B

4. FILL THE DIFFERENTIAL WITH GEAR OIL.

NOTE: Refer to the RECOMMENDED LUBRICANTLIST.

Oil Capacity: Approx. 5.5L (5.81 U.S.Qt./4.84 lmp.Qt.)

Models FF and SG (SH16-1 Series) REAR AXLE 10-33

1 page 1

DIFFERENTIAL CARRIER(HINO SH16-1 series for models FF and SG)

1. Flange lock nut2. Flange yoke coupling3. Dust deflector4. Oil seal5. Taper roller bearing6. Bearing cage7. Shim8. Name plate9. Spacer

10. Drive pinion11. Cylindrical roller bearing12. Retainer ring

13. Differential carrier case14. Adjust nut15. Differential case16. Side gear thrust washer17. Side gear18. Pinion thrust washer19. Pinion20. Spider21. Ring gear22. Collar23. Bearing cap24. Lock plate

2

SM10-419

Fig. 1

34

56

7

145

15

16 17 18

1920

2223

24

15

145

21

24

13

8

24

1211

10

59

1

SM10-419A

Model FF

Model SG

Models FF and SG (SH16-1 Series)10-34 REAR AXLE1 page 1

REMOVAL1. REMOVAL OF DIFFERENTIAL CARRIER

NOTE: Be sure to apply wheel stoppers in the frontand rear of the front tires.

Fig. 2

SM10-420

1. Disconnect the propeller shaft from the flange at thedifferential carrier.

NOTE: Draw the aligning marks on the flange andyoke before disassembling.

Fig. 3

SM10-421

2. Remove the filler and the drain plug to drain the gearoil from the axle housing.

WARNINGDo not work on differential carrier while it is stillhot.This can result in personal injury.

Fig. 4

SM10-422

3. Remove the bolts, and then pull the axle shafts out.

Fig. 5

SM10-423

4. Use a jack to dismount the differential carrier assem-bly from the axle housing.

WARNING● When loosening the tightened bolts of the dif-

ferential carrier, do not place yourself under thedifferential carrier.

● Be sure to apply a support before dismountingthe differential carrier assembly.

Fig. 6

SM10-424B

Models FF and SG (SH16-1 Series) REAR AXLE 10-351 page 1

DISASSEMBLY1. DISASSEMBLY OF THE DIFFERENTIAL CARRIER

1. Mount the differential carrier assembly on a workstand.

Fig. 7

SM10-425

2. Loosen the bolts, then remove the bearing cap fromthe differential carrier.

NOTE: First apply match marks to the cap and car-rier.

Special Tool: Socket wrench (09603-1150)

Fig. 8

SM10-426A

3. Remove the differential case assembly from the car-rier.

Fig. 9

SM10-427

4. Remove the taper roller bearings at both ends of thedifferential case by using a puller.

NOTE: ● Do not change the combination of theassembled taper roller bearing and itsrace.

● Always replace the bearings with theiroriginal races.

Fig. 10

SM10-428

5. Loosen the bolts and remove the ring gear from thedifferential case.

NOTE: Be careful not to drop the ring gear from thedifferential case.

Fig. 11

SM10-429


6. Disassemble the differential case.

NOTE: Be sure to check the aligning marks on thedifferential case before disassembly. Re-move the bolts so that the case separates.

7. Loosen the bolts and remove the pinion assembly,and then remove the cylindrical roller bearing fromthe differential carrier.

Fig. 13

SM10-433

8. 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 willcause damage to the threads of the drive pin-ion when loosening the nut.

Special Tool: Socket wrench (09839 - 4601)Fig. 14

SM-434B

10. Remove the taper roller bearing from the pinion gearusing a puller.

Fig. 16

SM10-437

SM10-435

Fig. 12

SM10-430

SM10-432

9. Separate the bearing cage and the pinion gear witha press.

Fig. 15

SM10-436


11. Remove the retainer ring and then pull out the innerrace for cylindrical roller bearing from the pinion gearusing a puller.


12. Remove the oil seal and the taper roller bearing outerraces from the cage.

NOTE: At the same time that the bearing is drawnout, the oil seal comes out. Be careful not todeform the oil seal.

Fig. 18

SM10-440

INSPECTION1. INSPECTION OF THE DIFFERENTIAL CARRIER

1. Check the flange coupling spline for wear and dam-age.Replace the coupling if damaged or worn.

Fig. 19

SM10-442

2. Inspect the taper roller bearings, cylindrical rollerbearing and races for burns or pitting.If such defects are found, replace it.

Fig. 20

SM10-444

3. Inspect the drive pinion and ring gear teeth surfacesfor wear, stripping or damage, and replace both partsas a set when defects are found.

NOTE: The drive pinion and ring gear must be re-placed as a set, not individually, because theyare fitted to each other by lapping duringmanufacture.Replacement of only one part does not pro-duce proper tooth contact, and gear strengthdrops excessively.Fig. 21

SM10-445A

Fig. 17

SM10-439SM10-438

SM10-443


4. Inspect the spider holes and surfaces of the differ-ential case that come in contact with the thrust wash-ers for wear or damage. Replace the case, if dam-aged or worn.

Fig. 22

SM10-446

5. Inspect the pinion for wear or damage and check theamount of wear of the bore with a cylinder gauge.

Fig. 23

SM10-447

Fig. 24

SM10-448

7. Measure the thickness of the thrust washers on thepinion and side gears. Replace any washer wornbeyond the limit.

Standard Thickness:Side gear 1.9 - 2.1 mm (0.075 - 0.082 in.)Pinion gear 1.7 - 1.9 mm (0.067 - 0.074 in.)

Service Limit:Side gear 1.7 mm (0.067 in.)Pinion gear 1.5 mm (0.059 in.)

Fig. 25

SM10-450

6. Inspect the spider for damage, and check the amountof wear by measuring its journals with a micrometerto determine the spider to pinion clearance.When the clearance is beyond the service limit, re-place it.

Standard clearance: 0.140 - 0.261 mm(0.0056 - 0.0102 in.)


SM10-449A


8. Measure the pinion backlash by using a dial gaugewith a magnet base.When the backlash is beyond the service limit, re-place the pinion gear and/or side gear.

Assembly standard: 0.20 - 0.60 mm(0.0079 - 0.0236 in.)


Put the side gear in the differential case so that thechamfering surface of the thrust washer is on thegear side.

Fig. 26

SM10-451

9. Measure the backlash of the side gear and pinionwith the cogs of the pinion and side gear in the posi-tion shown in Fig. 27, D.

A Pinion B Side gear

C Thrust washer D Correct

E Incorrect

Fig. 27

SM10-269B

A

B

C

A

B

CORRECT

A

B

INCORRECT


3. Tighten the bolts to the specified torque.


Fig. 3

SM10-455

Fig. 4

SM10-456

Fig. 5

SM10-458

4. Install the taper roller bearing to both ends of the dif-ferential case using a press.

5. Install the cylindrical roller bearing inner race usinga press and install the retainer ring on the end of thedrive pinion.

WARNINGThe retainer ring is spring steel and may pop out.Wear safety glasses when installing.

SM10-457

ASSEMBLY1. ASSEMBLY AND ADJUSTMENT OF DIFFERENTIAL

CARRIER1. 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 (181-217 lb·ft)

Fig. 1

SM10-453SM10-452

2. Install the ring gear to the differential case.

NOTE: Apply the lock agent (Lock tight) which isequivalent to THREE BOND: 1360K onthreads.

Fig. 2

SM10-454


8. Put the spacer to drive pinion.

9. Using a press, assemble the bearing cage and ta-per roller bearing on the drive pinion.

Fig. 9

Fig. 10

SM10-464

SM10-463

Fig. 8

SM10-582A

10. Install the flange on the pinion shaft without oil seal,and then tighten the flange lock nut to the specifiedtorque using a special tool.

Special Tool: Socket wrench (09839 - 4601)Tightening Torque: 6,000 - 8,000 kg·cm

(434 - 578 lb·ft)

Fig. 6

SM10-459

6. Using a press, install the inner taper roller bearingto the drive pinion.

7. Using a press, install the taper roller bearing outerraces in the bearing cage.

Fig. 7

SM10-461SM10-460


b. Using a spring balancer.

Turning force: Unit: kg (lb)

Models FF SG

New bearing 3.2 - 4.0 (7.1 - 8.8) 2.7 - 3.3 (5.9 - 7.3)

Re-used bearing 2.4 - 3.2 (5.3 - 7.0) 2.0 - 2.6 (4.5 - 5.8)

12. When the preload is correct, remove the flange andthen install the new oil seal, flange and flange locknut.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 (09839 - 4601)Tightening Torque: 6,000 - 8,000 kg·cm (434 - 578 lb·ft)

Fig. 13

SM10-466

13. Lock the flange lock nut by staking the lip into thepinion shaft slots.

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 10-46.Fig. 14

SM10-494SM10-467B

Fig. 12

SM10-116

SM10-487

1.5 mm

10 mm

a. Using a torque wrench.

11. Measure the preload of the drive pinion bearings.If the preload is out of the specified limits, adjust itas following.Use a thinner spacer to increase and a thicker oneto decrease preload. When new bearings, use thespacer of 17.425 mm (0.686 in.) at first and meas-ure the preload. This will be helpful to select thespacer for specified preload.Tighten the flange lock nut to the specified torquebefore re-checkingFig. 11

SM10-465

New bearing Re-used bearing

Turning torque 20 - 25 kg·cm (1.5 - 1.8 lb·ft) 15 - 20 kg·cm (1.1 - 1.4 lb·ft)

Adjusting spacer thickness 17 differences in thicknesses from 17.25 to 17.65 mm (0.680 to 0.694 in.)each differing 0.025 mm (0.001 in.)


a. Pinion depth gauge setting methodSet the pinion depth gauge onto the master bed,confirm the dimensions B, C, and D, and then setthe dial gauge to “0”.Dimension B = Nominal pinion fitting height “A”

Fig. 17

SM10-059B

B C D

Height33.0 mm 29.65 mm 28.35 mm(1.30 in.) (1.167 in.) (1.12 in.)

MASTER BED

DC B

A

14. Install the pinion assembly and the cylindrical rollerbearing on the differential carrier.

NOTE: At this point, align mark on the bearing cageand the other one on the differential carriercase.

Fig. 15

15. Measure the drive pinion fitting height (conical dis-tance) 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 shimto increase the pinion fitting height.

Nominal Pinion Fitting Height “A”: 33.0 mm (1.30 in.)Special Tool: Pinion depth gauge (09640-1151)

Fig. 16

SM10-469

b. Use method for the pinion depth gaugeSet the pinion depth gauge as shown in the figureon the left, and read the value of the dial gauge.A : Measuring pinion-fitting height valueE : Engraved value for gear toothing adjustmentF : Adjusting shims

Fig. 18

SM10-059A

E

F

Example: If the engraved value at the surface of the pin-ion 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.)

Adjust the pinion fitting heightto this value.

Nominal pinion fitting height “A”Fig. 19

SM10-470A

“a”

Adjusting Shims Thickness 0.3 mm (0.012 in.) 0.4 mm (0.016 in.) 0.45 mm (0.0177 in.) 0.5 mm (0.020 in.)

SM10-468A


16. Tighten the differential carrier cage bolts to the speci-fied torque.

NOTE: Apply the sealing compound which is equiva-lent to THREE BOND No. 1215 to the fittingfaces of the carrier and the cage.


17. Install and tighten the bearing lock plates with boltsand nuts then lock the nuts by staking as shown.

Tightening Torque : 190 - 260 kg·cm (14 - 18 lb·ft)

18. Mount the differential case assembly on the differ-ential carrier.

19. Install the adjusting nut and bearing cap on the dif-ferential carrier and tighten the cap temporarily withbolts.

NOTE: Align the match marks of the cap and the dif-ferential carrier.

Fig. 20

Fig. 21

Fig. 22

Fig. 23

SM10-471

SM10-493

SM10-427

SM10-473A

SM10-472

A

20. Adjust the preload of the side bearing by using aspecial tool.

1) Tighten the adjusting nut on the back side of the ringgear 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 (09665 - 1040)

Fig. 24

SM10-475SM10-474


21. Strike the bearing cap with a copper hammer.

Fig. 25

SM10-476A

22. Measure the gear backlash at four points using a dialgauge with a magnet stand. If the measured valueis out of specified value, adjust the gear backlash byturning the adjusting nuts, loosening one side onenotch and tightening the other side one notch.

Assembly Standard: 0.25 - 0.33 mm (0.0099 - 0.0129 in.)(gear ratio: 4.100 and 5.857)0.30 - 0.41 mm (0.0119 - 0.0161 in.)(gear ratio: 4.625 and 5.428)

Special Tool: Adjuster tool (09665 - 1040)Fig. 26

SM10-540

23. Inspection of gear tooth contacta. Satisfactory gear tooth contacta) The length of the tooth contact area in the direction

of the tooth trace should be more than half the lengthof L, and the tooth contact area should be at the toeside.

b) Tooth pressure should be distributed evenly over thecontact area of the tooth.

SM10-477

Fig. 27

SM10-72A

NOTE: On new gears there is a blade-applying markfrom lapping. Adjust the contact area to alignwith this mark.

Fig. 28

SM10-478A

DecreaseIncrease

Models FF and SG (SH16-1 Series)10-46 REAR AXLE

1 page 1

A B

Fig. 30

SM10-072C

Fig. 31

SM10-479

Turning torque: Unit: kg·cm (lb·ft)Models SG1J SG

Gear ratio 4.100 4.625 5.428 5.857

New 4.9 - 6.1 4.4 - 5.4 3.7 - 4.6 3.5 - 4.2bearing (0.36 - 0.44) (0.32 - 0.39) (0.27 - 0.33) (0.25 - 0.30)

Re-used 3.7 - 4.8 3.3 - 4.3 2.8 - 3.6 2.6 - 3.4bearing (0.27 - 0.35) (0.24 - 0.31) (0.20 - 0.26) (0.19 - 0.24)

A B

Fig. 29

SM10-072B

Turning torque: Unit: kg·cm (lb·ft)Models FF

Gear ratio 5.428 5.857

New 3.7 - 4.6 3.5 - 4.2bearing (0.27 - 0.33) (0.25 - 0.30)

Re-used 2.8 - 3.6 2.6 - 3.4bearing (0.20 - 0.26) (0.19 - 0.24)

24. Measure the total preload of the differential carrierbearings.

NOTE: Total preload = Pinion bearing preload (Meas-ured at step 13. in page 10 - 42) + Side bear-ing preload (Refer to tables below).

If the preload is out of the specified limits, adjust itwith the adjusting nuts of the side bearings.Tighten both side adjusting nuts evenly to increaseand loosen them to decrease preload and re-inspectthe gear tooth contact.

Special Tool: Adjuster tool (09665 - 1040)1. Using a torque wrench.

b) Heel and face contact.

A: Replace (Heel contact)

B: Adjust (Face contact)

b. Samples of unsatisfactory engagement.a) Toe and Flank contact.

A: Replace (Toe contact)

B: Adjust (Flank contact)

Models FF and SG (SH16-1 Series) REAR AXLE 10-47

1 page 1

26. Install the lock plate.

Tightening Torque: 190 - 260 kg·cm (14 - 18 lb·ft)

Fig. 34

SM10-482

25. Tighten the bearing cap bolts to the specified torque.


Fig. 33

SM10-481

2. Using a spring balancer.

Fig. 32

SM10-480

Turning force: Unit: kg (lb)Models SG1J SG

Gear ratio 4.100 4.625 5.428 5.857

New 0.65 - 0.81 0.58 - 0.72 0.50 - 0.61 0.46 - 0.57bearing (1.44 - 1.79) (1.28 - 1.58) (1.09 - 1.35) (1.01 - 1.25)

Re-used 0.49 - 0.65 0.44 - 0.57 0.37 - 0.49 0.35 - 0.45bearing (1.08 - 1.43) (0.96 - 1.27) (0.82 - 1.08) (0.76 - 1.00)

Turning force: Unit: kg (lb)Models FF

Gear ratio 5.428 5.857

New 0.59 - 0.73 0.55 - 0.68bearing (1.30 - 1.62) (1.21 - 1.50)

Re-used 0.45 - 0.59 0.41 - 0.54bearing (0.98 - 1.30) (0.91 - 1.20)


Fig. 5

Fig. 3

SM10-484

3. INSTALL THE AXLE SHAFT.


Fig. 4

SM10-485

2. INSTALL THE PROPELLER SHAFT TO DIFFERENTIALCARRIER 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

650 - 870 kg·cm (47 - 62 lb·ft)For model SG1,300 - 1,600 kg·cm (94 - 115 lb·ft)

INSTALLATION1. 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 equiva-lent to THREE BOND#1215.

NOTE: Be careful not to install the differential car-rier upside down. Install the differential car-rier so that the ring gear teeth face to the rightside of the vehicle. Otherwise the vehicle willmove backward while the transmission isshifted into forward gear.


5 mm (0.20 in.)

3 mm (0.12 in.)

Fig. 1

SM10-541

Fig. 2

SM10-483

SM10-486

4. FILL THE DIFFERENTIAL WITH GEAR OIL.

NOTE: Refer to the RECOMMENDED LUBRICANTLIST.

Oil Capacity: Approx. 10.0 L(10.57 U.S.Qt./8.80 lmp.Qt.)

chapter 10 rear axle - tgidirect.com service manual...chapter 10 rear axle models fd, fe, ... 19....

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