DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE) Hyster

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
(WET BRAKE)
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
[G004, H004, J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT)
[N005, P005, R005, S005, U005]
PART NO. 1624740 1400 SRM 1246

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Identification Plate ............................................................................................................................................. 1
Drive Axle Removal .................................................................................................................................................1
Hub Seal Replacement ............................................................................................................................................8
Remove ................................................................................................................................................................ 9
Install .................................................................................................................................................................12
Planetary Reduction Repair ................................................................................................................................. 17
Remove .............................................................................................................................................................. 18
Disassemble .......................................................................................................................................................20
Clean and Inspect ............................................................................................................................................. 26
Assemble ............................................................................................................................................................26
Install .................................................................................................................................................................36
Brake Repair ..........................................................................................................................................................40
Remove and Disassemble ................................................................................................................................. 42
Assemble and Install ........................................................................................................................................ 52
Bevel Pinion ...........................................................................................................................................................62
Remove .............................................................................................................................................................. 63
Disassemble .......................................................................................................................................................65
Assemble ............................................................................................................................................................68
Calculation of Measurement Y .................................................................................................................... 70
Calculation of Measurement X .................................................................................................................... 71
Calculation of Measurement S1 ...................................................................................................................72
Calculation of Measurement S2 ...................................................................................................................72
Bevel Pinion Housing ................................................................................................................................... 74
Install .................................................................................................................................................................78
Differential Unit ....................................................................................................................................................80
Remove .............................................................................................................................................................. 81
Disassemble .......................................................................................................................................................90
Differential Assembly ...................................................................................................................................90
Ring Nuts ...................................................................................................................................................... 96
Assemble ............................................................................................................................................................97
Ring Nuts ...................................................................................................................................................... 97
Differential Assembly .................................................................................................................................100
Install ...............................................................................................................................................................107
Drive Axle Installation ........................................................................................................................................120
Special Tools ........................................................................................................................................................ 128
Torque Specifications .......................................................................................................................................... 129
This section is for the following models:
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004, H004, J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
[N005, P005, R005, S005, U005]
©2015 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1400 SRM 1246 General
General
This manual covers the repair of the drive axle,
differential, and the wet disc brakes.
IDENTIFICATION PLATE
See Figure 1.
1. DANA PART NUMBER

2. DANA SERIAL NUMBER
3. HYSTER PART NUMBER
4. AXLE OVERALL RATIO
Figure 1. Identification Plate
Drive Axle Removal

or death. Never loosen nuts that hold together in-
WARNING ner and outer wheel halves when there is air pres-
When putting the lift truck on blocks, make sure sure in tire.
the surface is solid, even, and level. Any blocks
used to support the lift truck must be solid, one- 4. Remove the wheels.
piece units.
5. Remove the planetary carrier housing fill/level
1. Put blocks on each side (front and back) of the plugs on both sides of the drive axle.
steering tires to prevent movement of the lift
See Figure 2 for lift truck models
truck.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
2. Raise the lift truck and put blocks under the 120FT; S80, 100FTBCS; S120FTS;
frame so that the drive wheels do not touch the S120FTPRS) (G004, H004, J004)
floor. Put blocks under the counterweight for
stability. See Figure 3 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
3. Remove the mast assembly as described in the H5.0-5.5FT (H80, 90, 100, 110, 120FT)
section Mast Repairs (S/N A513, A514, A613, (N005, P005, R005, S005, U005)
A614, A702, A703, A704, A705, A706, A707,
A751, A752, B513, B514, B586, B587, B588, 6. Remove the center section fill/level plug.
B589, B590, B591, B749, B750, B751, B752,
B753, B754) 4000SRM1250. See Figure 2 for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
WARNING 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004, J004)
On lift trucks with pneumatic tires, completely re-
move air from tires before removing them from lift
truck. Air pressure in tires can cause tire and rim
parts to explode, which can cause serious injury
1
Drive Axle Removal 1400 SRM 1246

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005,U005)
7. Remove the planetary carrier housing drain

plugs on both sides of the drive axle to drain
the oil from the planetary carrier housings into
a suitable container.

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004, J004)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005, U005)
8. Remove the center section drain plug to drain

the oil from the center section into a suitable
container. A. REAR VIEW SHOWN
B. FRONT VIEW SHOWN
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
120FT; S80, 100FTBCS; S120FTS; 2. PLANETARY CARRIER HOUSING DRAIN
S120FTPRS) (G004, H004, J004) PLUGS
3. CENTER SECTION DRAIN PLUG
See Figure 3 for lift truck models 4. CENTER SECTION FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, 6. PLANETARY CARRIER HOUSING (LH)
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 7. CENTER SECTION
(N005, P005, R005, S005, U005)
Figure 2. Drive Axle Drain and Fill/Level Plugs for
Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004, J004)
2
1400 SRM 1246 Drive Axle Removal
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
See Wet Brakes - NMHG 1800SRM1597 for lift

truck models
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
S120FTPRS) (J004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(U005)
10. Remove the capscrews retaining the line guards

and remove the line guards on both sides of the
drive axle.

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (G004, H004, J004)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005, U005)
11. Disconnect the brake cooling lines from both

sides of the drive axle.

A. REAR VIEW SHOWN
B. FRONT VIEW SHOWN • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
1. PLANETARY CARRIER HOUSING FILL/LEVEL S120FTPRS) (G004, H004, J004)
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS See Figure 5 for lift truck models
3. CENTER SECTION FILL/LEVEL PLUG • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
4. CENTER SECTION DRAIN PLUG H5.0-5.5FT (H80, 90, 100, 110, 120FT)
6. PLANETARY CARRIER HOUSING (LH) (N005, P005, R005, S005, U005)
7. CENTER SECTION
12. Disconnect the brake lines from both sides of
Figure 3. Drive Axle Drain and Fill/Level Plugs for the drive axle.
Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) See Figure 4 for lift truck models
(N005, P005, R005, S005, U005)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
9. Remove the parking brake cables. Refer to the S120FTPRS) (G004, H004, J004)
following section for removal procedures:
See Brake System 1800SRM1247 for lift truck
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
models
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, (N005, P005, R005, S005, U005)
S120FTPRS) (G004, H004)
3
1. BRAKE COOLING LINE (LEFT SIDE) 7. CAPSCREW

2. HOSE CLAMP 8. COOLING RETURN HOSES
3. HOSE CLAMP 9. CAPSCREW
4. BRAKE COOLING LINE (RIGHT SIDE) 10. LINE GUARD (LEFT SIDE)
5. BRAKE LINE (RIGHT SIDE) 11. BRAKE LINE (LEFT SIDE)
6. LINE GUARD (RIGHT SIDE)
Figure 4. Brake Cooling Lines and Brake Lines, Lift Truck Model S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
4
1. BRAKE COOLING LINE (LEFT SIDE) 5. BRAKE LINE (LEFT SIDE)

3. BRAKE COOLING LINE (RIGHT SIDE) 7. BRAKE LINE SUPPLY LINE
4. BRAKE LINE (RIGHT SIDE)
Figure 5. Brake Cooling Lines and Brake Lines, Lift Truck Model H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
5
13. Disconnect the cooling return hoses from the 15. Place blocks under the transmission to support
drive axle. See Figure 6. the transmission while removing the drive axle.
14. Place blocks under the axle assembly and con- 16. Remove the capscrews holding the drive shaft
nect slings and lifting device. and remove the drive shaft.
A. DRIVE AXLE COOLING HOSE RETURN TO TRANSMISSION SUMP

1. HOSE CLAMP 3. COOLING RETURN HOSE, LEFT SIDE
2. COOLING RETURN HOSE, RIGHT SIDE
Figure 6. Drive Axle Cooling Return Hoses
6
17. Remove the transmission isolator mounting Legend for Figure 7

bolt located on top of the assembly. See Fig-
ure 7. 1. ISOLATORS 4. CAPSCREW
2. WASHER 5. TRANSMISSION
3. WASHER 6. DRIVE AXLE
18. Remove the four mounting capscrews and

washers from the drive axle. See Figure 8.
19. Remove blocks and lower the drive axle assem-

bly. Pull axle forward and away from frame.
20. Place blocks under the differential assembly.
Figure 7. Transmission to Differential Mounting

Bolt
1. CAPSCREW 3. DRIVE AXLE

2. WASHER
Figure 8. Drive Axle Mounting Capscrews
7
Hub Seal Replacement
1. SEAL 5. RING NUT

2. EXTERNAL BEARING 6. SAFETY FLANGE
3. HUB 7. SOCKET HEAD SCREW
4. WASHER 8. COVER
Figure 9. Hub Seal Replacement
8
1400 SRM 1246 Hub Seal Replacement
REMOVE
Refer to Figure 9.
STEP 1.
Remove the cover from the hub.
1. COVER
STEP 2.
Mark the position of the ring nut.
Remove the socket head screw and the safety flange

from the ring nut.
1. SOCKET HEAD SCREW

2. SAFETY FLANGE
9
Hub Seal Replacement 1400 SRM 1246
STEP 3.
Using special tool T1, loosen the ring nut.
1. SPECIAL TOOL T1
STEP 4.
Remove the ring nut and washer.
1. RING NUT
2. WASHER
STEP 5.
Using a puller, loosen the hub assembly.
1. HUB ASSEMBLY
10
STEP 6.
By hand, finish removing the hub assembly.
1. HUB ASSEMBLY
NOTE: It may be necessary to use a puller to remove the external bearing.
STEP 7.
Remove the external bearing.
1. EXTERNAL BEARING
STEP 8.
Remove the seal from the hub.
1. SEAL
11
INSTALL
Refer to Figure 9.
CAUTION
Make sure the seal is positioned correctly in the
hub or damage may occur.
STEP 1.
Position the seal in the hub.
1. SEAL
2. HUB
CAUTION
When installing the sealing ring, make sure to
maintain the predefined distance of 21.4 to
21.8 mm (0.842 to 0.858 in.) for pneumatic lift
trucks, and 8.9 to 9.1 mm (0.350 to 0.358 in.) for
cushion lift trucks. Refer to STEP 3.
STEP 2.
Position the special tool T2 for cushion lift trucks
or special tool T3 for pneumatic lift trucks on the
seal and press the seal into the hub.
NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL

TOOL T3 IS SIMILAR.
1. SPECIAL TOOL T2
12
STEP 3.
Verify the depth of the seal is correct. 8.9 to
9.1 mm (0.350 to 0.358 in.) for cushion lift trucks,
and 21.4 to 21.8 mm (0.842 to 0.858 in.) for pneu-
matic lift trucks.
Check the flatness of the seal.
NOTE: CUSHION LIFT TRUCK SHOWN.
NOTE: PNEUMATIC LIFT TRUCK SHOWN.
13
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
STEP 4.
Install the external bearing. If necessary, use a
suitable drift pin to prevent damage.
Alternatively, heat the bearing to 100°C (212°F).
1. EXTERNAL BEARING
STEP 5.
Install the hub assembly.
1. HUB ASSEMBLY
STEP 6.
Install the washer.
Apply Loctite® 242 to the arm thread and manually

thread the ring nut onto the arm thread.
1. APPLY LOCTITE® 242

2. WASHER
3. RING NUT
14
STEP 7.
Lock the wheel hub in position with a lever.
Tighten the ring nut as follows:
a. Using special tool T1, tighten ring nut to

237 N•m (175 lbf ft).
b. Rotate hub 2 to 3 revolutions in both direc-

tions.
c. Using special tool T1, tighten ring nut to

406 N•m (300 lbf ft).
d. Rotate hub 2 to 3 revolutions in both direc-

tions. 1. SPECIAL TOOL T1
STEP 8.
Tighten the ring nut to 500 to 600 N•m (369 to
443 lbf ft).
NOTE: It may be necessary to move ring nut in the tightening direction to allow alignment of the safety
flange to socket head screw hole.
STEP 9.
Apply Loctite® 242 to the threads of the socket
head screw. Place the safety flange in position and
install the socket head screw into one of the three
holes.

2. SAFETY FLANGE
15
STEP 10.
Tighten the socket head screw to 9.5 to
10.5 N•m (84 to 93 lbf in).
CAUTION
Do not damage the contact surfaces of the cover
when installing.
STEP 11.
Apply Loctite® 510 to the cover and install the
cover into the hub.
16
1400 SRM 1246 Planetary Reduction Repair
Planetary Reduction Repair
NOTE: THE S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004);
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
SERIES LIFT TRUCK DRIVE AXLE WILL HAVE TWO BRAKE DISCS AND TWO FRICTION PLATES. THE
S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) SERIES LIFT TRUCK DRIVE AXLE WILL ONLY HAVE ONE
BRAKE DISC AND ONE FRICTION PLATE.
1. COVER 14. O-RING
2. SOCKET HEAD SCREW 15. PLANETARY CARRIER
3. SAFETY FLANGE 16. NEEDLE BEARINGS
4. RING NUT 17. PLANETARY GEAR
5. WASHER 18. RETAINING RING
6. HUB 19. DOWEL PIN
7. EXTERNAL BEARING 20. RING GEAR
8. INTERNAL BEARING 21. THRUST WASHER
9. SEAL 22. O-RING
10. CAPSCREW 23. PINION
11. PLANETARY COVER 24. AXLE SHAFT
12. MAGNETIC PLUG 25. FRICTION PLATE
13. PLUG 26. BRAKE DISC
Figure 10. Planetary Reduction Assembly
17
Planetary Reduction Repair 1400 SRM 1246
REMOVE
Refer to Figure 10.
STEP 1.
Remove the cover from the hub.
1. COVER
STEP 2.
Mark the position of the ring nut.
Remove the socket head screw and the safety flange

from the ring nut.

2. SAFETY FLANGE
STEP 3.
Using a special tool T1, loosen the ring nut.
1. SPECIAL TOOL T1
18
WARNING
The hub and planetary carrier assembly are
heavy. Use caution when removing.
STEP 4.
Place a sling around the hub and planetary car-
rier assembly and connect the sling to an over-
head lift. Place the sling under light tension.
Remove the capscrews from the planetary cover.
1. HUB AND PLANETARY CARRIER ASSEMBLY

2. CAPSCREW
STEP 5.
Remove the hub and planetary carrier assembly.
19
DISASSEMBLE
Refer to Figure 10.
STEP 1.
Remove the O-ring.
STEP 2.
Remove the pinion.
1. PINION
NOTE: The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004);
series lift truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT;
S80FTBCS) (G004, H004, J004) series lift truck drive axle will only have one brake disc and one friction
plate.
NOTE: Note the order of position of the brake discs and friction plates before removing them. If the brake
discs and friction plates are not being replaced, do not switch their positions.
NOTE: Replace discs when the groove depth thickness is less than 0.1 mm (0.0039 in.).
20
STEP 3.
Remove the friction plate.
1. FRICTION PLATE
STEP 4.
Remove the brake disc.
1. BRAKE DISC
2. FRICTION PLATE
NOTE: STEP 5 and STEP 6 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS;
S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005, P005, R005, S005, U005) series lift trucks only.
STEP 5.
Remove the second friction plate.
1. FRICTION PLATE
21
STEP 6.
Remove the second brake disc.
STEP 7.
Remove the ring gear.
1. RING GEAR
STEP 8.
Remove the ring nut and washer.
1. RING NUT 2. WASHER
22
STEP 9.
Remove the snap rings.
1. SNAP RING
NOTE: Note the assembly side of the planetary gears.
STEP 10.
Remove the planetary gears.
1. PLANETARY GEAR
STEP 11.
Remove the planetary carrier from the planetary
cover.
1. PLANETARY CARRIER
23
STEP 12.
Using a puller, loosen the planetary cover from
the hub.
1. PLANETARY COVER
STEP 13.
Remove the internal bearing.
1. INTERNAL BEARING
STEP 14.
Remove the planetary cover from the hub.
1. PLANETARY COVER
24
STEP 15.
Remove the internal and external bearing cones
from the planetary cover.
1. INTERNAL BEARING CONE

2. EXTERNAL BEARING CONE
NOTE: It may be necessary to use a puller to remove the external bearing.
STEP 16.
Remove the external bearing.
1. EXTERNAL BEARING
STEP 17.
Remove the seal from the hub.
1. SEAL
25
CLEAN AND INSPECT 2. Inspect the bearings and bearing cups for dam-
age. If either bearing or bearing cup is dam-
aged, replace both bearings and bearing cups.
WARNING Also replace the inner hub seal.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Inspect the all parts for wear and damage. Re-
solvents, always follow the solvent manufactur- place parts as needed.
er's recommended safety precautions.
4. Inspect the brake disc(s). Replace discs when
1. Clean all the parts with solvent. the groove depth thickness is less than
0.1 mm (0.0039 in.).
ASSEMBLE
Refer to Figure 10.
CAUTION
Make sure the seal is positioned correctly in the
hub or damage may occur.
STEP 1.
Position the seal in the hub.
1. SEAL 2. HUB
CAUTION
When installing the sealing ring, make sure to
maintain the predefined distance of 8.9 to
cushion lift trucks. Refer to STEP 3.
STEP 2.
Position the special tool T2 for cushion lift trucks
or special tool T3 for pneumatic lift trucks on the
seal and press the seal into the hub.
NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL

TOOL T3 IS SIMILAR.
1. SPECIAL TOOL T2
26
STEP 3.
Verify the depth of the seal is correct. 8.9 to
cushion lift trucks.
Check the flatness of the seal.
NOTE: PNEUMATIC LIFT TRUCK SHOWN.
NOTE: CUSHION LIFT TRUCK SHOWN.
27
WARNING
prevent burns.
STEP 4.
Install the external bearing. If necessary, use a
suitable drift pin to prevent damage.
Alternatively, heat the bearing to 100°C (212°F).
1. EXTERNAL BEARING
STEP 5.
Using a press, install the internal and external
bearing cones.
NOTE: INTERNAL BEARING CONE SHOWN BE-

ING PRESSED INTO THE PLANETARY COVER.
28
STEP 6.
Place the planetary cover in position on the hub.
1. PLANETARY COVER
STEP 7.
Using a plastic hammer, drive the planetary cover
to the limit stop by lightly hammering around the
edge.
29
STEP 8.
Place the internal bearing in position. With a
plastic hammer and metal punch fixture, tap the
bearing in position until it is set in the bearing
cone.
STEP 9.
Check the position/stop of the internal bearing.
1. INTERNAL BEARING
30
STEP 10.
Replace the O-ring on the planetary carrier. Lu-
bricate the new O-ring with a lithium based
grease before installing.
1. O-RING
STEP 11.
Install the planetary carrier into the planetary
cover.
1. PLANETARY CARRIER
31
STEP 12.
Install the planetary gears onto the planetary car-
rier with the assembly side of the gears as noted
in STEP 10 of Disassemble.
1. PLANETARY GEAR
STEP 13.
Install the snap rings to retain the planetary
gears to the planetary carrier.
1. SNAP RING
STEP 14.
Install the washer.
Manually thread the ring nut onto the arm thread

but do not tighten.
1. RING NUT 2. WASHER
32
STEP 15.
Install the ring gear onto the planetary gears.
1. RING GEAR
STEP 16.
Lubricate the internal spline of the pinion with
John Deere JDM J20C and install the pinion.
1. PINION
plate.
NOTE: If installing the brake discs and friction plates for a S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS;
S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005, U005) series lift trucks, install the brake discs and friction plates in
the same position as removed.
33
STEP 17.
Lightly lubricate the friction plate with John
Deere JDM J20C and place it in position on the
arm.
1. FRICTION DISC
STEP 18.
Lightly lubricate the brake disc with John Deere
JDM J20C and place it in position on the arm.
1. BRAKE DISC
NOTE: STEP 19 through STEP 21 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS;
STEP 19.
When installing the brake discs, make sure that
the circulation holes and the marks "B" are per-
fectly lined up.
When installing the friction disc, the slot corre-

sponding to the oil level cap should always be kept
free.
34
STEP 20.
Lightly lubricate the second friction plate with
John Deere JDM J20C and place it in position on
the arm.
1. FRICTION DISC
STEP 21.
Lightly lubricate the second brake disc with John
arm.
1. BRAKE DISC
35
INSTALL
Refer to Figure 10.
CAUTION
The oil outlet must be on the bottom side.
STEP 1.
Lubricate a new O-ring with a lithium based
grease and install the O-ring on the planetary
cover.
Place the hub and planetary carrier assembly in po-

sition on the drive axle.
1. PLANETARY COVER
2. O-RING
STEP 2.
Apply Loctite® 242 to the capscrews.
Install the capscrews to retain the hub and plane-

tary carrier assembly to the drive axle.

2. CAPSCREW
36
STEP 3.
Tighten the capscrews to 199 to 243 N•m (147 to
179 lbf ft).
STEP 4.
Lock the wheel hub in position with a lever.
Using a special tool T1, tighten the ring nut as fol-

lows:
a. Remove ring nut and apply Loctite® 242 to

the arm thread. Reinstall ring nut.
b. Using a special tool T1, tighten ring nut to

237 N•m (175 lbf ft).
c. Rotate hub 2 to 3 revolutions in both direc-

tions.
d. Using a special tool T1, tighten ring nut to 1. SPECIAL TOOL T1

406 N•m (300 lbf ft).
e. Rotate hub 2 to 3 revolutions in both direc-

tions.
37
STEP 5.
Tighten the ring nut to 500 to 600 N•m (369 to
443 lbf ft).
NOTE: It may be necessary to move ring nut in the tightening direction to allow alignment of the safety
flange to socket head screw hole.
STEP 6.
head screw. Place the safety flange in position and
install the socket head screw into one of the three
holes.

2. SAFETY FLANGE
38
STEP 7.
Tighten the socket head screw to 9.5 to
10.5 N•m (84 to 93 lbf in).
CAUTION
Do not damage the contact surfaces of the cover
when installing.
STEP 8.
Apply Loctite® 510 to the cover and install the
cover into the hub.
39
Brake Repair 1400 SRM 1246
Brake Repair
Figure 11. Brake Assembly
40
1400 SRM 1246 Brake Repair
Legend for Figure 11

NOTE: THE S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004);
SERIES LIFT TRUCK DRIVE AXLE WILL HAVE TWO BRAKE DISCS AND TWO FRICTION PLATES. THE
S4.0FT, (S80FT; S80FTBCS) (G004, H004, J004) SERIES LIFT TRUCK DRIVE AXLE WILL ONLY HAVE ONE
BRAKE DISC AND ONE FRICTION PLATE.
1. SOCKET HEAD SCREW 14. O-RING

2. PARKING BRAKE LEVER 15. PISTON
3. O-RING 16. SPRING
4. SOCKET HEAD SCREW 17. SOCKET HEAD/PIN SCREW
5. O-RING 18. SPRING
6. BEARING 19. CAPSCREW
7. THRUST LEVER (PARKING BRAKE) 20. SPACER
8. CAP 21. ADJUSTER/STOP SCREW
9. BLEEDER SCREW 22. NUT
10. DOWEL PIN 23. THRUST BUSHING
11. DISC 24. FRICTION PLATE*
12. TUBE (PART OF PISTON ASSEMBLY) 25. BRAKE DISC*
13. O-RING
*SEE NOTE ABOVE.
41
REMOVE AND DISASSEMBLE

Refer to Figure 11.
WARNING
The hub and planetary carrier assembly are heavy. Use caution when removing.
STEP 1.

2. CAPSCREW
STEP 2.
42
STEP 3.
Remove the O-ring.
STEP 4.
Remove the pinion.
1. PINION
NOTE: STEP 5 and STEP 6 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS;
The S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004); H4.0FT5/
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005) series lift
truck drive axle will have two brake discs and two friction plates. The S4.0FT, (S80FT; S80FTBCS) (G004,
H004, J004) series lift truck drive axle will only have one brake disc and one friction plate.
NOTE: Note the order of position of the brake discs and friction plates before removing them. If the discs
and plates are not being replaced, do not switch their positions.
43
STEP 5.
Remove the friction plate.
1. FRICTION PLATE
STEP 6.
Remove the brake disc.
1. BRAKE DISC
2. FRICTION PLATE
STEP 7.
Remove the second friction plate.
1. FRICTION PLATE
44
STEP 8.
Remove the second brake disc.
STEP 9.
Remove the ring gear.
1. RING GEAR
CAUTION
If the socket head/pin screws are being replaced,
note down the positions and the different colors
for the different brake gaps.
STEP 10.
Remove the socket head/pin screws guiding the
piston.
1. SOCKET HEAD/PIN SCREW
45
STEP 11.
Remove the capscrews and return springs from
the piston.
1. CAPSCREW
2. RETURN SPRING
46
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
CAUTION
Hold onto the piston as it may be suddenly ejec-
ted and damaged.
STEP 12.
Mark the position of the piston.
Slowly apply compressed air through the brake

fluid port to extract the entire piston.
1. PISTON
STEP 13.
Remove the axle shaft.
NOTE: The O-rings must be replaced each time the unit is disassembled.
47
STEP 14.
Remove and discard the O-rings from the piston.
1. PISTON 3. O-RING
2. O-RING
STEP 15.
Remove the socket head screw retaining the park-
ing brake lever.

2. PARKING BRAKE LEVER
NOTE: Mark the parking brake lever in relation to the thrust lever.
STEP 16.
Remove the spacer and the parking brake lever.
1. SPACER
48
STEP 17.
Remove the socket head screws retaining the
thrust bushing.

2. THRUST BUSHING
3. THRUST LEVER
STEP 18.
Remove the thrust bushing.
1. THRUST BUSHING
STEP 19.
Remove and discard the O-ring.
1. O-RING
49
STEP 20.
1. O-RING
STEP 21.
Mark the position of the thrust lever.
Remove the thrust lever with bearings.
50
STEP 22.
Using a press, remove the bearings from the
thrust lever.
CLEAN AND INSPECT 3. Inspect the all parts for wear, damage, and
rust. Replace parts as needed.
WARNING 4. Inspect the brake disc(s). Replace discs when
Cleaning solvents can be flammable and toxic and the groove depth thickness is less than
can cause skin irritation. When using cleaning 0.1 mm (0.0039 in.).
solvents, always follow the solvent manufactur-
er's recommended safety precautions. The groove depth thickness for a new disc is 0.3
to 0.5 mm (0.0118 to 0.0197 in.).
1. Clean all the parts with solvent.
2. Inspect the bearings for wear or damage. Re-

place as needed.
51
ASSEMBLE AND INSTALL

Refer to Figure 11.
WARNING
prevent burns.
STEP 1.
Heat the bearings to approximately 100°C (212°F)
and install the bearings on the thrust lever.
1. BEARING
STEP 2.
Lubricate the thrust lever and bearings with John
Deere JDM J20C and install the thrust lever in
position previously marked during removal.
1. THRUST LEVER
STEP 3.
Lubricate new O-rings with a lithium based
grease and install the O-rings on the thrust bush-
ing.
Pack the area above the O-ring with multipurpose

grease with 2% to 4% molybdenum disulfide prior
to installing thrust bushing onto thrust lever.
1. O-RING
2. O-RING
3. APPLY MULTIPURPOSE GREASE HERE
52
STEP 4.
Install the thrust bushing.
Apply Loctite® 242 to the socket head screws and

install the socket head screws and tighten to 21 to
30 N•m (15 to 22 lbf ft).

2. THRUST BUSHING
STEP 5.
Install the parking brake lever in the position
marked previously in disassembly.

STEP 6.
Install the spacer and socket head screw.

2. SPACER
53
STEP 7.
Tighten the socket head screw to 21 to
30 N•m (15 to 22 lbf ft).

STEP 8.
Install the axle shaft.
NOTE: The piston relief must face downwards when installed.
STEP 9.
grease and install new O-rings onto the piston.
1. PISTON 3. O-RING
2. O-RING
54
STEP 10.
Install the stroke automatic regulation springs
flush in the piston.
1. STROKE AUTOMATIC REGULATION SPRING

2. PISTON
STEP 11.
Lubricate the O-rings and the piston and install
the piston into the arm. Lightly tap around the
edge of the piston with a plastic hammer until the
piston is seated.
1. PISTON
NOTE: The thread holes must be free of oil.
STEP 12.
Apply Loctite® 270 to the threads of the capscrews
and install the capscrews and return springs.
Tighten the capscrews to 10 to 15 N•m (88.5 to
132.8 lbf in).
55
CAUTION
Be sure to install the socket head/pin screws in
the positions previously noted down during disas-
sembly. The different colors of the socket
head/pin screws are for the different brake gaps.
STEP 13.
head/pin screws.
1. SOCKET HEAD/PIN SCREWS
STEP 14.
Install the socket head/pin screws and tighten to 5
to 7 N•m (44 to 62 lbf in).
STEP 15.
If necessary, replace the alignment dowel pins. In-
stall the new dowel pins with only 5 mm (0.20 in.)
of the length into the housing.
1. DOWEL PIN
56
STEP 16.
1. PINION
plate.
NOTE: If installing the brake discs for a lift trucks with two brake discs and two friction plates, install the
brake discs and friction plates in the same position as removed.
STEP 17.
Lightly lubricate the friction plate with John
arm.
1. FRICTION DISC
57
STEP 18.
Lightly lubricate the brake disc with John Deere
JDM J20C and place it in position on the arm.
1. BRAKE DISC
NOTE: STEP 19 through STEP 21 are for S4.5, 5.5FT, S5.5FTS, (S100, 120FT; 100FTBCS; S120FTS;
STEP 19.
When installing the brake discs, make sure that
the circulation holes (not fully round holes) and
the marks B are perfectly lined up.
When installing the friction disc, the slot corre-

sponding to the oil level cap should always be kept
free.
B. CIRCULATION HOLES (NOT FULLY ROUND

HOLES)
STEP 20.
Lightly lubricate the second friction plate with
John Deere JDM J20C and place it in position on
the arm.
1. FRICTION DISC
58
STEP 21.
Lightly lubricate the second brake disc with John
arm.
1. BRAKE DISC
CAUTION
The oil outlet/drain plug must be on the bottom
side.
STEP 22.
cover.

1. PLANETARY COVER
2. O-RING
59
1. OIL LEVEL/FILL PLUG

2. OIL OUTLET/DRAIN PLUG
STEP 23.


2. CAPSCREW
60
STEP 24.
179 lbf ft).
STEP 25.
Apply light pressure to the parking brake lever to
bring it to rest with the piston without pre-loading
the inside band.
Adjust the adjustment screw to draw near to the

parking brake lever, leaving a 0.1 to
0.2 mm (0.0039 to 0.0079 in.) gap.

2. ADJUSTMENT SCREW
CAUTION
The idle stroke should be eliminated without pre-
loading the parking brake lever.
STEP 26.
Lock the adjustment screw in position with the
nut. Tighten the nut to 20 to 25 N•m (14.75 to
18.44 lbf ft).

2. ADJUSTMENT SCREW
3. NUT
61
Bevel Pinion 1400 SRM 1246
Bevel Pinion
1. PLUG 9. BEVEL PINION HOUSING

2. FLANGE (YOKE) 10. SHIM
3. RETAINING RING 11. SPACER
4. PLATE 12. BEARING
5. SEAL 13. O-RING
6. RING NUT 14. BEVEL PINION
7. BEARING 15. PLUG
8. SPACER 16. CAPSCREW
Figure 12. Bevel Pinion Assembly
62
1400 SRM 1246 Bevel Pinion
REMOVE
Refer to Figure 12.
STEP 1.
Remove the capscrews retaining the transmission
support and remove the support.
STEP 2.
Remove the flange (yoke).
1. FLANGE (YOKE)
STEP 3.
Remove the capscrews retaining the bevel pinion
cover.
1. CAPSCREW
63
NOTE: Mark the position of the bevel pinion housing to the drive axle housing.
STEP 4.
Using two capscrews, extract the bevel pinion
housing assembly.
STEP 5.
Remove the bevel pinion housing assembly.
1. BEVEL PINION HOUSING
64
DISASSEMBLE
Refer to Figure 12.
STEP 1.
Remove the seal.
1. SEAL
STEP 2.
Place the bevel pinion housing assembly on a
workbench.
Using special tool T4, lock the pinion in place and

loosen the ring nut.
1. SPECIAL TOOL T4
STEP 3.
Remove the ring nut.
1. RING NUT
65
STEP 4.
Using a puller, remove the bevel pinion, spacers,
and bearings from the housing.
1. BEVEL PINION
STEP 5.
Bevel pinion, spacers, and bearings removed.
1. SPACER 3. BEARING
2. BEVEL PINON
STEP 6.
Remove the calibrated spacers.
1. SPACER 2. SPACER
66
STEP 7.
Using a press, remove the bearing.
1. BEVEL PINION 2. BEARING

STEP 8.
Remove the bearing cups from the bevel pinion
housing.
STEP 9.
Remove the shims from the bevel pinion housing.
1. SHIMS
67
CLEAN AND INSPECT Clean and inspect the following parts:

• Bearings - Inspect the cup, cone, rollers,
WARNING and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear,
Cleaning solvents can be flammable and toxic and
cracks, or damage, replace with new bearing
can cause skin irritation. When using cleaning
cone and cup.
solvents, always follow the recommendations of
the manufacturer. • Bevel Pinion - Inspect the bevel pinion for
wear or damage. Replace as needed. If the
bevel pinion is replaced, the bevel gear must
WARNING also be replaced.
Compressed air can move particles so that they
• Bevel Pinion Housing - Inspect the hous-
cause injury to the user or to other personnel.
ing for wear and damage. Replace as needed.
Make sure that the path of the compressed air is
ASSEMBLE
Refer to Figure 12 and Figure 13.
68
Figure 13. Determining Bevel Pinion Shim Thickness
69
Calculation of Measurement Y
STEP 1.
Reset a centesimal digital depth gauge on a
20 mm (0.787 in.) calibrated block.
1. 20 mm (0.787 in.) CALIBRATED BLOCK
STEP 2.
With the calibrated block on a faceplate, allow the
bearing to set by rotating them in both directions
and by applying a vertical thrust to position the
calibrated block on the external thrust blocks.
Check the overall thickness of the bearing (D).
Example:
D = 35.25 mm
1. D = BEARING THICKNESS
STEP 3.
Determine the actual bevel pinion mounting dis-
tance I. See Figure 13.
Example:
I = INT ± V
• 98 − 0.1 = 97.9 mm
Determine measurement Y.
Example:
Y=I+D
• 97.9 + 35.25 = 133.15 mm
70
Calculation of Measurement X
STEP 1.
Measure the case diameter (210 mm).
Example:
R = central body radius
• 210 ÷ 2 = 105 = 105 mm
STEP 2.
Measure the thickness of the central body at the
pinion bearing contact surface.
Example:
B = 24.15 mm
STEP 3.
Reset a centesimal digital depth gauge. With
depth gauge (set to zero at previous point) meas-
ure surface between the contact surface and the
striking surface of the internal bearing (E).
Example:
E = pinion support thickness
• E = 5.3 mm
Determine measurement X.
Example:
X=R+B+E
• 105 + 24.15 + 5.3 = 134.45 mm
71
Calculation of Measurement S1
STEP 1.
Determine the thickness of the shims S1. See Fig-
ure 13.
Example:
S1 = X − Y
• 134.45 − 133.15 = 1.3 mm
STEP 2.
Install the shims.
1. SHIMS
Calculation of Measurement S2
STEP 1.
Place the special tool T5 in position under the
press.
Place the bearing cup and bevel pinion housing in

position on the special tool T5.
1. SPECIAL TOOL T5
72
STEP 2.
Place the opposite bearing cup in position and in-
stall the bearing cups using the special tool T5.
1. BEARING CUP
2. SPECIAL TOOL T5
STEP 3.
Assemble the special tool T6 with bearings into
the bevel pinion housing as shown. Hand tighten
until the axial gap is eliminated.
1. BEARING
3. SPECIAL TOOL T6
4. BEARING
STEP 4.
Insert the tip of the depth gauge into either side
hole of the special tool T6.
Reset the depth gauge with a preload of approxi-

mately 3 mm.
NOTE: Refer to Figure 12.
73
STEP 5.
Install the spacer (11) and largest calibrated
spacer (8) between the bearings, assembled with
the special tool T6. Insert the tip of the depth
gauge into either side hole and measure the devia-
tion H from the previous reset in STEP 4.
Example:
H = A − B = 2.93 mm
1. SPECIAL TOOL T6
NOTE: Refer to Figure 12.
STEP 6.
The deviation H measured must be added to the
fixed value X to define the pack S2, installed be-
tween the bearings (7, 12) and the spacer (11).
The value S2 must be rounded to the upper 5/100.
Example:
S2 = H + X
H=A−B
X = 0.10 to 0.11 mm (fixed value)
Bevel Pinion Housing
WARNING
prevent burns.
STEP 1.
Heat the inner bearing to approximately
100°C (212°F) and install the bearing onto the
bevel pinion.
Once the bearing has cooled down, lightly lubricate

the bearing with John Deere JDM J20C.
Install the bevel pinion into the bevel pinion hous-

ing.
74
WARNING
prevent burns.
STEP 2.
Install the calibrated spacers as shown.
Heat the outer bearing to approximately

100°C (212°F) and install the bearing onto the
bevel pinion.
Once the bearing has cooled down, lightly lubricate

the bearing with John Deere JDM J20C.
STEP 3.
Apply Loctite® 270 to the threads of the ring nut
and screw the ring nut onto the pinion.
1. RING NUT
STEP 4.
Using the special tool T4, tighten the bevel pinion
ring nut to a torque setting of 400 to
500 N•m (295 to 369 lbf ft).
1. SPECIAL TOOL T4
75
CAUTION
If the rolling torque exceeds the maximum value, then the size of the calibrated spacer (8) S2 between the
bearing (7) and distance spacer (11) needs to be increased. See Figure 12.
If the rolling torque does not reach the set value, increase the torque setting of the ring nut in different
stages to obtain a maximum value of 500 N•m (369 lbf ft).
CAUTION
If the rolling torque does not reach the minimum value, then the size of the calibrated spacer (8) S2 be-
tween the bearing (7) and distance spacer (11) needs to be decreased. See Figure 12.
STEP 5.
Measure the rolling torque of the bevel pinion.
The rolling torque should be 1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
NOTE: Only apply oil to the lip of the seal using John Deere JDM J20C.
76
STEP 6.
Using the special tool T7, install the seal.
1. SPECIAL TOOL T7
77
INSTALL
Refer to Figure 12.
STEP 1.
grease and install on the bevel pinion housing.
STEP 2.
Apply Loctite® 242 to the threads of the retaining
capscrews for the bevel pinion housing.
Place the bevel pinion housing in position and in-

stall the capscrews. Tighten the capscrews in a
cross pattern to 68 to 75 N•m (50 to 55 lbf ft).
1. CAPSCREW
78
STEP 3.
Lubricate the pinion splines with a lithium based
grease.
Install the flange (yoke).
1. FLANGE (YOKE)
STEP 4.
capscrews for the transmission support.
Place the transmission support in position and in-

stall the capscrews. Tighten the capscrews to 182 to
202 N•m (134 to 149 lbf ft).
79
Differential Unit 1400 SRM 1246
Differential Unit
1. SOCKET HEAD SCREW 10. THRUST WASHER

2. RING NUT 11. SIDE GEAR
3. SEAL 12. DIFFERENTIAL PIN COUPLER
4. SNAP RING 13. PINION GEAR
5. O-RING 14. SPHERICAL THRUST WASHER
6. ROLLER BEARING 15. DOWEL
7. CENTERING RING/BUSHING 16. PIN
8. CAPSCREW 17. PIN
9. BEVEL GEAR 18. DIFFERENTIAL CARRIER
Figure 14. Differential Assembly
80
1400 SRM 1246 Differential Unit
REMOVE
Refer to Figure 14.
CAUTION
The hub and planetary carrier assembly are heavy. Use caution when removing.
STEP 1.

2. CAPSCREW
STEP 2.
81
CAUTION
If the socket head/pin screws are being replaced,
note down the positions and the different colors
for the different brake gaps.
STEP 3.
Remove the socket head/pin screws guiding the
piston.

STEP 4.
Remove the capscrews and return springs from
the piston.
82
1. CAPSCREW
2. RETURN SPRING
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure
that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield
to prevent injury to the eyes.
WARNING
Hold onto the piston as it may be suddenly ejected and damaged.
STEP 5.
Mark the position of the piston.
Slowly apply compressed air through the brake fluid port to extract the entire piston.
83
1. PISTON
STEP 6.
Remove the axle shaft.
NOTE: The O-rings must be replaced each time the unit is disassembled.
STEP 7.
Remove and discard the O-rings from the piston.
1. PISTON 3. O-RING
2. O-RING
84
STEP 8.
Remove the socket head screw retaining the park-
ing brake lever.

NOTE: Mark the parking brake lever in relation to the thrust lever.
STEP 9.
Remove the spacer and the parking brake lever.
1. SPACER
STEP 10.
Remove the socket head screws retaining the
thrust bushing.

2. THRUST BUSHING
3. THRUST LEVER
85
STEP 11.
Remove the thrust bushing.
1. THRUST BUSHING
STEP 12.
1. O-RING
STEP 13.
1. O-RING
86
STEP 14.
Mark the position of the thrust lever.
Remove the thrust lever with bearings.
STEP 15.
Repeat STEP 1 through STEP 14 on the opposite
side.
STEP 16.
Remove the capscrews retaining the transmission
support and remove the transmission support.
87
CAUTION
Check and make note of the static torque before
removal/disassembly.
STEP 17.
Measure the static torque of the bevel pinion and
bearings.
STEP 18.
Remove the bevel pinion housing assembly. Refer
to Bevel PinionRemove.

STEP 19.
Mark the position of the ring nuts on both sides of
the assembly.
Remove the socket head screws from the ring nuts

on both sides of the assembly.

2. RING NUT
88
STEP 20.
Using the special tool T8, remove the ring nuts on
both sides of the assembly.
1. SPECIAL TOOL T8
2. RING NUT
STEP 21.
Place a sling around the arm to be removed and
connect the sling to an overhead hoist.
Remove the nuts and slide the arm from the threa-
ded studs.
STEP 22.
If the bearings of the differential assembly need
replaced, remove the bearing cup from the arm.
1. BEARING CUP
89
STEP 23.
Remove the differential assembly from the central
body.
STEP 24.
If the bearings of the differential assembly need
replaced, remove the bearing cups from the cen-
tral body.
1. BEARING CUP
DISASSEMBLE
Refer to Figure 14.
Differential Assembly
STEP 1.
Remove the bearing from the differential carrier.
1. BEARING
2. DIFFERENTIAL CARRIER
90
STEP 2.
Remove the bearing from the bevel gear side.
1. BEARING
2. BEVEL GEAR
STEP 3.
If the centering rings/bushings need replaced, use
a puller and remove the centering ring/bushing
from both sides of the differential carrier.
91
STEP 4.
Remove the capscrews retaining the bevel gear.
STEP 5.
Remove the bevel gear from the differential car-
rier.
1. BEVEL GEAR
2. DIFFERENTIAL CARRIER
STEP 6.
Remove the thrust washer and side gear.
1. SIDE GEAR
2. THRUST WASHER
92
STEP 7.
Remove the pins from the differential pin coupler.
1. PIN
STEP 8.
With a pin-driver, push the two short differential
pins to the outside of the differential carrier.
1. DIFFERENTIAL PIN
STEP 9.
Remove the long pin with the help of a brass drift.
93
STEP 10.
Remove the two short pins with the help of a
brass drift.
STEP 11.
Remove the differential pin coupler.
1. DIFFERENTIAL PIN COUPLER
94
STEP 12.
Remove the pinion gears and spherical thrust
washers.
1. PINION GEAR
2. SPHERICAL THRUST WASHER
STEP 13.
Remove the remaining side gear and thrust
washer.
1. SIDE GEAR
2. THRUST WASHER
95
Ring Nuts
Perform the following procedures on both ring nuts.
STEP 1.
Remove the snap ring from the ring nut.
STEP 2.
Remove the seal from the ring nut.
STEP 3.
Remove and discard the O-ring from the ring nut.
1. O-RING
96
CLEAN AND INSPECT • Tapered roller bearings - Inspect the cup,

cone, rollers, and cage of all tapered roller
bearings in the assembly. If bearings show
WARNING signs of wear, cracks, or damage, replace
Cleaning solvents can be flammable and toxic and with new bearing.
can cause skin irritation. When using cleaning
• Bevel Pinion and bevel gear - Inspect the
solvents, always follow the recommendations of
bevel pinion and bevel gear for wear or dam-
the manufacturer.
age. If the bevel pinion or bevel gear is dam-
aged, they must be replaced as a set.
WARNING • Pinions and side gears - Inspect the pin-
Compressed air can move particles so that they ions and side gears for wear or damage. Pin-
cause injury to the user or to other personnel. ions and side gears that are worn or dam-
Make sure that the path of the compressed air is aged must be replaced.
• Main differential assembly - Inspect all
parts of the main differential assembly for
wear or damage. Parts that are damaged
Clean and inspect the following parts of the differ-
must be replaced.
ential:
• Drive axle - Clean the parts of the axle with ASSEMBLE
solvent and dry with compressed air. Inspect
all machined surfaces and bearings for wear Refer to Figure 14.
and damage.
Ring Nuts
Perform the following procedures on both ring nuts.
STEP 1.
Lubricate the outer surface of the new seal with a
lithium based grease and install the new seal into
the ring nut with special tool T9 to a predeter-
mined depth of 8.35 to 8.65 mm (0.329 to
0.341 in.).
1. SEAL 3. SPECIAL TOOL T9

2. RING NUT
97
STEP 2.
Install the snap ring.
Rotate the snap ring to verify that it is properly set

in the groove.
1. SNAP RING
STEP 3.
Lubricate a new O-ring and install the O-ring onto
the ring nut.
1. O-RING
98
STEP 4.
If the arms are replaced, apply Loctite® 510 to two
new setscrews and install the setscrews in the
holes on the opposite side of the ring nut socket
head screws.
1. SETSCREWS
1. SETSCREW
3. RING NUT
99
Differential Assembly
STEP 1.
Lubricate a thrust washer and side gear.
Install the thrust washer and side gear into the dif-
ferential carrier.
1. SIDE GEAR
2. THRUST WASHER
STEP 2.
Lubricate the short pins with John Deere JDM
J20C.
Insert a pinion gear and spherical thrust washer

into the differential carrier and insert a short pin to
keep the pinion gear and thrust washer in position.
Repeat this step on the opposite side.
1. SHORT PIN
3. PINION GEAR
100
STEP 3.
Verify that the holes in the short pins are verti-
cally located.
STEP 4.
Lubricate the long pin with John Deere JDM
J20C.
Partially insert the long pin into the differential

carrier and install a spherical thrust washer and
pinion gear.

2. PINION GEAR
3. SHORT PIN
4. LONG PIN
STEP 5.
Temporarily install a dummy pin in the opposite
side and install the remaining spherical thrust
washer and pinion gear.
101
STEP 6.
Place the differential pin coupler in the correct po-
sition in the differential carrier.
1. DIFFERENTIAL PIN COUPLER
STEP 7.
Insert the long pin through the coupler until it
pushes the dummy pin out of the opposite side of
the differential carrier.
Insert the short pins into the coupler.
STEP 8.
Verify that the holes in the short and long pins
are lined up with the holes in the differential pin
coupler.
Insert the new spring pins into the differential pin

coupler.
102
1. SPRING PIN
STEP 9.
Verify that the spring pins are completely en-
gaged into the journals of the differential pin cou-
pler to prevent damage as the side gear rotates.
STEP 10.
Insert the side gear into the differential carrier.
1. SIDE GEAR
103
STEP 11.
Apply multipurpose grease to the bevel gear
thrust washer surface.
Place the thrust washer into position on the bevel

gear.
1. BEVEL GEAR
STEP 12.
Place the bevel gear into position on the differen-
tial carrier.
Apply Loctite® 270 to the retaining capscrews and

install the capscrews.
1. BEVEL GEAR
2. CAPSCREW
STEP 13.
Tighten the capscrews using a cross pattern to
139 to 154 N•m (102.5 to 113.6 lbf ft).
104
STEP 14.
Lubricate the outer surface of the centering ring/
bushing with John Deere JDM J20C and place the
centering ring/bushing in position on the bevel
ring side of the differential carrier.
STEP 15.
Install the centering ring/bushing into the differ-
ential carrier.
STEP 16.
Lubricate the outer surface of the remaining cen-
tering ring/bushing with John Deere JDM J20C
and place the centering ring/bushing in position
on the opposite side of the bevel ring of the differ-
ential carrier.
105
STEP 17.
Install the centering ring/bushing into the differ-
ential carrier.
WARNING
prevent burns.
STEP 18.
Heat the bearing to 100°C (212°F) and install the
bearing onto the differential carrier.
1. BEARING
STEP 19.
Heat the bearing to 100°C (212°F) and install the
bearing onto the differential carrier.
1. BEARING
106
INSTALL
Refer to Figure 14.
STEP 1.
Place the special tool T8 into the arm to support
the differential assembly.
1. SPECIAL TOOL T8
STEP 2.
Install the differential assembly into the central
body.
STEP 3.
If the bearings are being replaced, install new
bearing cups into the arm and central body.
1. BEARING CUP
107
STEP 4.
Lubricate a new O-ring and install the new O-ring
onto the arm.
STEP 5.
Place the arm in position on the threaded studs to
the central body.
Apply Loctite® 242 to the threaded studs and in-

stall the retaining nuts. Tighten the nuts to 129 to
143 N•m (95 to 105.5 lbf ft).
STEP 6.
grease and install on the bevel pinion housing.
108
STEP 7.
capscrews for the bevel pinion housing.
Place the bevel pinion housing in position and in-

stall the capscrews. Tighten the capscrews in a
cross pattern to 68 to 75 N•m (50 to 55 lbf ft).
1. CAPSCREW
STEP 8.
Apply Loctite® 242 to the threads of the ring nuts
and install the ring nuts on both sides but do not
tighten.
1. RING NUT
109
STEP 9.
Tighten the ring nut on the bevel gear side until
the clearance between the bevel pinion and the
bevel gear is 0 mm (0 in.). Lock the bevel gear,
then loosen the ring nut 1/4 to ½ turn.
CAUTION
If the bearings are not new, check the static tor-
que and verify the static torque did not change
from the measurement recorded during removal.
If the bearings are new, check the continuous tor-

que.
STEP 10.
Preset the bearings by tightening the ring nut on
the opposite side of the bevel gear, so as to in-
crease pinion torque up to 1.6 to 2.2 N•m (14 to
19.5 lbf in).
STEP 11.
Lubricate the pinion splines with a lithium based
grease.
Install the flange (yoke).
1. FLANGE (YOKE)
110
STEP 12.
Block the bevel gear by installing a 30 mm long,
22 × 1.5 mm threaded bolt.
STEP 13.
Install a dial gauge as shown and shift the flange
to check the tolerance between the bevel gear
teeth.
Manually move the bevel gear in both directions to

check the existing backlash between the bevel pin-
ion and bevel gear.
A. 50 mm (1.9685 in.)
111
STEP 14.
Adjust the backlash between the bevel pinion and
the bevel gear by loosening one of the ring nuts
and tightening the opposite ring nut.
The backlash must be set between 0.25 to

0.34 mm (0.0098 to 0.01339 in.).
STEP 15.
head screw and install the socket head screw into
one of the two holes to lock the ring nut in posi-
tion. Tighten the socket head screw to 23.8 to
26.2 N•m (17.6 to 19.3 lbf ft). Repeat on opposite
side.
STEP 16.
Lubricate the thrust lever and bearings with John
Deere JDM J20C and install the thrust lever in
position previously marked during removal.
1. THRUST LEVER
112
STEP 17.
grease and install the O-rings on the thrust bush-
ing.
Pack the area above the O-Ring with multipurpose

grease with 2% to 4% molybdenum disulfide prior
to installing thrust bushing onto thrust lever.
1. O-RING
2. O-RING
3. APPLY MULTIPURPOSE GREASE HERE
STEP 18.
Install the thrust bushing.
Apply Loctite® 242 to the socket head screws and

install the socket head screws and tighten to 21 to
30 N•m (15 to 22 lbf ft).

2. THRUST BUSHING
STEP 19.
Install the parking brake lever in the position
marked previously in disassembly.
113
STEP 20.
Install the spacer and socket head screw.

2. SPACER
STEP 21.
Tighten the socket head screw to 21 to
30 N•m (15 to 22 lbf in).

STEP 22.
Install the axle shaft.
114
STEP 23.
grease and install new O-rings onto the piston.
1. PISTON 3. O-RING
2. O-RING
STEP 24.
Install the stroke automatic regulation springs
flush in the piston.
1. STROKE AUTOMATIC REGULATION SPRING

2. PISTON
STEP 25.
Lubricate the O-rings and the piston and install
the piston into the arm. Lightly tap around the
edge of the piston with a plastic hammer until the
piston is seated.
1. PISTON
NOTE: The thread holes must be free of oil.
115
STEP 26.
Apply Loctite® 270 to the threads of the capscrews
and install the capscrews and return springs.
Tighten the capscrews to 10 to 15 N•m (88.5 to
132.8 lbf in).
STEP 27.
head/pin screws.
1. SOCKET HEAD/PIN SCREWS

STEP 28.
Install the socket head/pin screws and tighten to 5
to 7 N•m (44 to 62 lbf in).
116
STEP 29.
If necessary, replace the alignment dowel pins. In-
stall the new dowel pins with only 5 mm (0.20 in.)
of the length into the housing.
1. DOWEL PIN
STEP 30.
1. PINION
CAUTION
The oil outlet/drain plug must be on the bottom
side.
STEP 31.
cover.

1. PLANETARY COVER
2. O-RING
117
1. OIL LEVEL/FILL PLUG

2. OIL OUTLET/DRAIN PLUG
STEP 32.


2. CAPSCREW
118
STEP 33.
179 lbf ft).
STEP 34.
Apply light pressure to the parking brake lever to
bring it to rest with the piston without pre-loading
the inside band.
Adjust the adjustment screw to draw near to the

parking brake lever, leaving a 0.1 to
0.2 mm (0.0039 to 0.0079 in.) gap.

2. ADJUSTMENT SCREW
CAUTION
The idle stroke should be eliminated without pre-
loading the parking brake lever.
STEP 35.
Lock the adjustment screw in position with the
nut. Tighten the nut to 20 to 25 N•m (14.75 to
18.44 lbf ft).
Repeat STEP 16 through STEP 35 on the opposite

side.

2. ADJUSTMENT SCREW
3. NUT
119
Drive Axle Installation 1400 SRM 1246
Drive Axle Installation

1. Connect slings and lifting device to drive axle. NOTE: It is recommended to use a torque multi-
plier to achieve the torque specification in Step 3.
NOTE: When installing the drive axle, ensure the
drive axle is held with the upper surface of the 3. Install the four mounting capscrews and wash-
drive axle against the frame. This will prevent any ers. Tighten the capscrews to 820 to
gaps between the frame and the drive axle mount, 902 N•m (605 to 665 lbf ft). See Figure 15.
and will ensure even weight distribution.
2. Position the drive axle in the lift truck.
1. CAPSCREW 3. DRIVE AXLE

2. WASHER
Figure 15. Drive Axle Mounting Capscrews
120
1400 SRM 1246 Drive Axle Installation
4. Place the drive shaft in position and install the 6. Remove blocks from under the transmission.
retaining capscrews. Tighten the drive shaft
capscrews to 50 to 63 N•m (37 to 46.5 lbf ft). 7. Connect the cooling return hoses to the drive
axle. See Figure 17.
5. Install the transmission isolator mounting bolt
located on top of the assembly. Tighten the bolt 8. Connect the brake lines to the drive axle.
to 225 to 250 N•m (166 to 184 lbf ft). See Fig-
ure 16.
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (G004, H004, J004)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005, U005)
9. Connect the brake cooling lines to the drive

axle.

• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (G004, H004, J004)

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005, S005, N005, P005, U005)
1. ISOLATORS 4. CAPSCREW
2. WASHER 5. TRANSMISSION
3. WASHER 6. DRIVE AXLE
Figure 16. Transmission to Differential Mounting
Bolt
121
A. DRIVE AXLE COOLING HOSE RETURN TO TRANSMISSION SUMP

1. HOSE CLAMP 3. COOLING RETURN HOSE, LEFT SIDE
2. COOLING RETURN HOSE, RIGHT SIDE
Figure 17. Drive Axle Cooling Return Hoses
122
1. BRAKE COOLING LINE (LEFT SIDE) 7. CAPSCREW

3. HOSE CLAMP 9. CAPSCREW
4. BRAKE COOLING LINE (RIGHT SIDE) 10. LINE GUARD (LEFT SIDE)
5. BRAKE LINE (RIGHT SIDE) 11. BRAKE LINE (LEFT SIDE)
6. LINE GUARD (RIGHT SIDE)
Figure 18. Brake Cooling Lines and Brake Lines, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004, J004)
123
1. BRAKE COOLING LINE (LEFT SIDE) 5. BRAKE LINE (LEFT SIDE)

3. BRAKE COOLING LINE (RIGHT SIDE) 7. BRAKE LINE SUPPLY LINE
4. BRAKE LINE (RIGHT SIDE)
Figure 19. Brake Cooling Lines and Brake Lines, Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005, U005)
10. Install parking brake cable. Make sure the 13. Install the center section drain plug and
brake cable is routed properly and has no inter- tighten to 30 to 50 N•m (22 to 37 lbf ft).
ference. Verify that the parking brake operates
properly. Refer to one of the following sections See Figure 20 for lift truck models
for procedures: • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
Brake System 1800SRM1247 for lift truck mod- S120FTPRS) (G004, H004, J004)
els
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, See Figure 21 for lift truck models
120FT; S80, 100FTBCS; S120FTS; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
S120FTPRS) (G004, H004) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; (N005, P005, R005, S005, U005)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
14. Install the planetary carrier housing drain
(N005, P005, R005, S005)
plugs on both sides of the drive axle and tighten
Wet Brakes - NMHG 1800SRM1597 for lift to 30 to 50 N•m (22 to 37 lbf ft).
truck models
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (J004)
S120FTPRS) (G004, H004, J004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) See Figure 21 for lift truck models
(U005) • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
11. Apply multipurpose grease to new O-ring and
(N005, P005, R005, S005, U005)
install O-ring on the drain plug.
12. Install the O-ring and drain plug.
124
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
PLUGS
4. CENTER SECTION FILL/LEVEL PLUG
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER SECTION B. FRONT VIEW SHOWN
Figure 20. Drive Axle Drain and Fill/Level Plugs for 1. PLANETARY CARRIER HOUSING FILL/LEVEL
Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S80, PLUGS
100, 120FT; S80, 100FTBCS; S120FTS; PLUGS
S120FTPRS) (G004, H004, J004) 3. CENTER SECTION FILL/LEVEL PLUG
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
Figure 21. Drive Axle Drain and Fill/Level Plugs for

Lift Truck Models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005, U005)
125
15. Fill the planetary gear housings and the drive • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
axle with the proper fluid. 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (J004)
Refer to Periodic Maintenance 8000SRM1248
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
for the correct fluid, quantity, and fill procedure
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
for lift truck models
(U005)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 16. Install the center section fill/level plug and
(N005, P005) tighten to 30 to 50 N•m (22 to 37 lbf ft).
S120FTPRS) (G004) • S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
Refer to Periodic Maintenance 8000SRM1558 S120FTPRS) (G004, H004, J004)
for lift truck models See Figure 21 for lift truck models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6, • H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT) H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(R005) (N005, P005, R005, S005, U005)
Refer to Periodic Maintenance 8000SRM1598 17. Install the planetary carrier housing fill/level
for the correct fluid, quantity, and fill procedure plugs on both sides of the drive axle and tighten
for lift truck models to 30 to 50 N•m (22 to 37 lbf ft).
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
S120FTPRS) (H004)
Refer to Periodic Maintenance 8000SRM1604 S120FTPRS) (G004, H004, J004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005, U005)
(S005)
Refer to Periodic Maintenance 8000SRM1902

126
18. Remove the air from the brake system. For pro- 19. On pneumatic lift trucks, inflate the tires using
cedures, refer to one of the following sections: a safety cage. Install the wheels and nuts and
tighten the nuts to 610 to 680 N•m (450 to
Brake System 1800SRM1247 for lift truck mod- 501 lbf ft).
els
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, NOTE: When tightening the wheel nuts, DO NOT
120FT; S80, 100FTBCS; S120FTS; use any lubricant on the studs or nuts.
S120FTPRS) (G004, H004)
20. On cushion lift trucks, install the wheel and
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; nuts and tighten the nuts to 610 to
H5.0-5.5FT (H80, 90, 100, 110, 120FT) 680 N•m (450 to 501 lbf ft).
(N005, P005, R005, S005)
21. Install the mast assembly as described in the
Wet Brakes - NMHG 1800SRM1597 for lift section Mast Repairs (S/N A513, A514, A613,
truck models A614, A702, A703, A704, A705, A706, A707,
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, A751, A752, B513, B514, B586, B587, B588,
120FT; S80, 100FTBCS; S120FTS; B589, B590, B591, B749, B750, B751, B752,
S120FTPRS) (J004) B753, B754) 4000SRM1250.
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6; 22. Raise the lift truck and remove blocks from un-
H5.0-5.5FT (H80, 90, 100, 110, 120FT) der frame and from under the counterweight.
(U005) Lower the lift truck.
23. Remove the blocks on each side (front and back)

WARNING of the steering tires.
Add air to the tires only in a safety cage. Inspect
safety cage for damage before use. When adding 24. Operate the lift truck and check for proper op-
air, use a clip-on chuck with enough hose to let eration and leaks.
the operator stand clear of the cage.
NOTE: When tightening the wheel nuts, use lubri-

cant on the studs or nuts.
127
Special Tools 1400 SRM 1246
Special Tools
Description Part Number Description Part Number
Wet Brake Axle 1639261 Wet Brake Axle 1639265
Service Tool T1 Service Tool T6
Wheel Hub/Planetary Nut Wet Brake Axle 1639266
Wet Brake Axle 1639262 Service Tool T7
Service Tool T2 Wet Brake Axle 1639267
Service Tool T3 Wet Brake Axle 1639268
Service Tool T4 Service Tool - Handle 1660310
Wet Brake Axle 1639264
Service Tool T5
128
1400 SRM 1246 Torque Specifications
Torque Specifications
Bevel Pinion Housing Capscrews Parking Brake Lever Socket Head Screw
21 to 30 N•m (15 to 22 lbf ft)
68 to 75 N•m (50 to 55 lbf ft)
Piston Guide Socket Head/Pin Screws
Bevel Pinion Ring Nut 5 to 7 N•m (44 to 62 lbf in)
400 to 500 N•m (295 to 369 lbf ft)
Planetary Carrier Cover to Drive Axle Cap-
Bevel Gear Capscrews screws
139 to 154 N•m (102.5 to 113.6 lbf ft) 199 to 243 N•m (147 to 179 lbf ft)
Differential Adjustment Ring Nut Socket Planetary Carrier Housing Drain Plug
Head Screw 30 to 50 N•m (22 to 37 lbf ft)
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Planetary Carrier Housing Fill/Level Plug
Drive Axle Arm to Drive Axle Central Body 30 to 50 N•m (22 to 37 lbf ft)
Nuts
129 to 143 N•m (95 to 105.5 lbf ft) Return Spring Capscrews
10 to 15 N•m (88.5 to 132.8 lbf ft)
Drive Axle Center Section Drain Plug
30 to 50 N•m (22 to 37 lbf ft) Safety Flange Socket Head Screw
21 to 30 N•m (15 to 22 lbf ft)
Drive Axle Center Section Fill/Level Plug
30 to 50 N•m (22 to 37 lbf ft) Thrust Bushing Socket Head Screws
21 to 30 N•m (15 to 22 lbf ft)
Drive Axle to Frame Mounting Capscrews
820 to 902 N•m (605 to 665 lbf ft) Transmission Isolator Mounting Bolt
225 to 250 N•m (166 to 184 lbf ft)
Drive Shaft Capscrews
50 to 63 N•m (37 to 46.5 lbf ft) Transmission Support Capscrews
182 to 202 N•m (134 to 149 lbf ft)
Hub Ring Nut
500 to 600 N•m (369 to 443 lbf ft) Wheel Nuts
610 to 680 N•m (450 to 501 lbf ft)
Parking Brake Lever Adjustment Screw Nut
20 to 25 N•m (14.75 to 18.44 lbf ft)
129
NOTES
130
TECHNICAL PUBLICATIONS
1400 SRM 1246 4/15 (12/13)(3/13)(9/12)(1/12)(5/09)

DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE) Hyster

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DRIVE AXLE AND

PART NO. 1624740 1400 SRM 1246

This section is for the following models:

©2015 HYSTER COMPANY i

1. DANA PART NUMBER

Figure 1. Identification Plate

Drive Axle Removal

See Figure 3 for lift truck models

7. Remove the planetary carrier housing drain

See Figure 2 for lift truck models

See Figure 3 for lift truck models

8. Remove the center section drain plug to drain

• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

See Wet Brakes - NMHG 1800SRM1597 for lift

10. Remove the capscrews retaining the line guards

See Figure 4 for lift truck models

See Figure 5 for lift truck models

11. Disconnect the brake cooling lines from both

See Figure 4 for lift truck models

1. BRAKE COOLING LINE (LEFT SIDE) 7. CAPSCREW

1. BRAKE COOLING LINE (LEFT SIDE) 5. BRAKE LINE (LEFT SIDE)

A. DRIVE AXLE COOLING HOSE RETURN TO TRANSMISSION SUMP

Figure 6. Drive Axle Cooling Return Hoses

17. Remove the transmission isolator mounting Legend for Figure 7

18. Remove the four mounting capscrews and

19. Remove blocks and lower the drive axle assem-

20. Place blocks under the differential assembly.

Figure 7. Transmission to Differential Mounting

1. CAPSCREW 3. DRIVE AXLE

Figure 8. Drive Axle Mounting Capscrews

Hub Seal Replacement

1. SEAL 5. RING NUT

Figure 9. Hub Seal Replacement

Remove the socket head screw and the safety flange

1. SOCKET HEAD SCREW

NOTE: It may be necessary to use a puller to remove the external bearing.

NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL

Check the flatness of the seal.

NOTE: CUSHION LIFT TRUCK SHOWN.

NOTE: PNEUMATIC LIFT TRUCK SHOWN.

Alternatively, heat the bearing to 100°C (212°F).

Apply Loctite® 242 to the arm thread and manually

1. APPLY LOCTITE® 242

Tighten the ring nut as follows:

a. Using special tool T1, tighten ring nut to

b. Rotate hub 2 to 3 revolutions in both direc-

c. Using special tool T1, tighten ring nut to

d. Rotate hub 2 to 3 revolutions in both direc-

1. SOCKET HEAD SCREW

Planetary Reduction Repair

Remove the socket head screw and the safety flange

1. SOCKET HEAD SCREW

Remove the capscrews from the planetary cover.

1. HUB AND PLANETARY CARRIER ASSEMBLY

1. HUB AND PLANETARY CARRIER ASSEMBLY

1. RING NUT 2. WASHER

1. INTERNAL BEARING CONE

NOTE: It may be necessary to use a puller to remove the external bearing.

NOTE: SPECIAL TOOL T2 SHOWN. SPECIAL