SERVICE REPAIR

H80FT H90FT H100FT H110FT H120FT [R005]

8000 SRM 1559 Lift Truck Lifting Capacity

Lift Truck Lifting Capacity

Model Weight
H4.0FT5, H4.0FT6 (H80FT) (R005) 3629 kg (8000 lb)
H4.5FTS5 (H90FT) (R005) 4082 kg (9000 lb)
H4.5FT6 (H100FT) (R005) 4536 kg (10000 lb)
H5.0FT (H110FT) (R005) 4989 kg (11000 lb)
H5.5FT (H120FT) (R005) 5443 kg (12000 lb)
NOTE: Load center at 500 mm (24 in.).

Counterweight Weights

Model Weight
H4.0FT5 (H80FT) (R005) 2172 kg (4788 lb)
H4.0FT6 (R005) 2370 kg (5225 lb)
H4.5FTS5 (H90FT) (R005) 2504 kg (5520 lb)
H4.5FT6 (H100FT) (R005) 2709 kg (5972 lb)
H5.0FT (H110FT) (R005) 3009 kg (6634 lb)
H5.5FT (H120FT) (R005) 3294 kg (7262 lb)

1
Tire Sizes 8000 SRM 1559

Tire Sizes

Truck Drive Tires Steer Tires

250 x 15 7.00 x 12

250 x 70 x R15 28 x 9 to 15

28 x 12.5 to 15
H4.0FT5, H4.5FTS5 (H80FT,
H90FT) (R005) 29 x 8 Dual

7.00 x 15 Dual

7.00 x R15 Dual

300 x 15 7.00 x 12

315 x 70 x R15 28 x 9 to 15

32 x 12.1 to 15
H4.5FT6, H5.0FT, H5.5FT
355 x 65 x 15
(H100FT, H110FT, H120FT)
(R005)
355 x 50 x 20

8.25 x 15 Dual

8.25 x R15 Dual

2
8000 SRM 1559 Capacities

Capacities
Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)

Item Quantity Specifications

Fuel Capacity
Gas (Short Wheel Base) 79 liter (20.8 gal) 86 Octane
Gas (Long Wheel Base) 100.3 liter (26.5 gal) 86 Octane
LPG 15.1 - 20.4 kg (33.5 - 45.0 lb) LPG-HD 5, HD 10
Full
Kubota 3.6L Diesel 79 liter (20.8 gal) Diesel No. 2
(Short Wheel Base)
Kubota 3.6L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Diesel No. 2
Kubota 3.8L Diesel 79 liter (20.8 gal) Low Sulfur ≤500 ppm or
(Short Wheel Base) Ultra Low Sulfur ≤15
ppm Diesel No.2
Kubota 3.8L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Low Sulfur ≤500 ppm or
Ultra Low Sulfur ≤15
ppm Diesel No.2
Engine Oil
−7°C (−20°F) and below
SAE 5W-20
16°C (60 °F) and below
PSI (GM) 4.3L 4.7 liter (5 qt) SAE 5W-30
−18°C (0°F) and above
SAE 10W-30 API SL IL-
SAC GF4
−25°C (−13°F) and above
SAE 10W-30
Below −25°C (−13°F)
Kubota Diesel 13.2 liter (13.9 qt) SAE 5W-20
−15°C (5°F) and above
SAE 15W-40
API CF or CI-4

3
Capacities 8000 SRM 1559

Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) (Continued)

Item Quantity Specifications

Cooling System

CAUTION
Additives may damage the
cooling system. Before using
additives, contact your local
PSI (GM) 4.3L 15.1 liter (15.9 qt) Hyster dealer.
Use Ethylene Glycol Boron-
free Antifreeze. Purchase a
pre-diluted 50/50 solution; or
mix 50% concentrate with 50%
distilled or deionized water.

CAUTION
Additives may damage the
cooling system. Before using
additives, contact your local
Kubota Diesel 11 liter (11.6 qt) Hyster dealer.
Use Ethylene Glycol Boron-
free Antifreeze. Purchase a
pre-diluted 50/50 solution; or
mix 50% concentrate with 50%
distilled or deionized water.
Hydraulic Tank Oil Capacity

CAUTION
Additives may damage the
hydraulic system. Before us-
62.0 liter (65.5 qt) ing additives, contact your lo-
PSI (GM) 4.3L (Short Wheel Base)
Drain and Fill cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above

CAUTION
Additives may damage the
hydraulic system. Before us-
78 liter (84 qt) ing additives, contact your lo-
PSI (GM) 4.3L (Long Wheel Base)
Drain and Fill cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above

4
8000 SRM 1559 Capacities

Table 1. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005) (Continued)

Item Quantity Specifications

CAUTION
Additives may damage the
hydraulic system. Before us-
62.0 liter (65.5 qt) ing additives, contact your lo-
Kubota Diesel (Short Wheel Base)
Drain and Fill cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above

CAUTION
Additives may damage the
hydraulic system. Before us-
78.0 liter (82.4 qt) ing additives, contact your lo-
Kubota Diesel (Long Wheel Base)
Drain and Fill cal Hyster dealer.
ISO VG-46 Hydraulic
Oil −15°C (5°F) and
above
Transmission (Dry Brake)
Basic Powershift Transmission 20 liter (21.0 qt) John Deere
JDM J20C
DuraMatch Transmission 20 liter (21.0 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder) 0.35 liter (0.74 pt) Dexron III
Differential and Drive Axle Oil 8.0 liter (8.5 qt) SAE 80W-90 or 85W-140
(Dry Brake)
Transmission and Wet Brake Drive Axle - Dana Axle Only
Transmission and Planetary Carrier 31.3 liter (33.0 qt) John Deere
Housing JDM J20C
Center body (Dana Axle Only) 2.0 liter (2.1 qt) SAE 80W-90
Wet Brake Drive Axle - NMHG Axle Only
New or Rebuilt Axle 10.3 liter (10.9 qt) John Deere
JDM J20C
Service Fill 9.3 liter (9.9 qt) John Deere
JDM J20C

5
Electrical System 8000 SRM 1559

Electrical System
Table 2. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)

Item PSI (GM) 4.3L Kubota Diesel

Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC-R44-LTS N/A
Spark Plug Gap 0.889 mm (0.035 in.) N/A
Ignition Timing:
Gas Not Adjustable N/A
LPG Not Adjustable N/A
Diesel N/A Not Adjustable

PSI (GM) 4.3L

Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750rpm 38 amps @ 750rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Kubota 3.6L Diesel
Alternator Output (13.5 Volts) D
Low Idle 30 amps @ 850 rpm
Governed Speed 80 amps @ 2400 rpm
Kubota 3.8L Diesel
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 825 rpm 25 amps @ 825 rpm
Governed Speed 80 amps @ 2325 rpm 45 amps @ 2325 rpm

6
8000 SRM 1559 Transmission Oil Pressures

Transmission Oil Pressures

1-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1 Transmission Pump Port 2 Port 3 Port 4 Port 5
***Low ***High Reverse Forward Torque Lubrication
Pressure Pressure Clutch Clutch Converter
1138 ±96* kPa 1482 ±96* kPa 983 ±58** kPa 983 ±58** kPa 738 ±52 kPa 138 ±34.5 kPa
(165 ±14 psi) (215 ±15 psi) (142.5 ±8.5 psi) (142.5 ±8.5 psi) (107 ±7.5 psi) (20 ±5 psi)

*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed
manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when
the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is
equipped with a wet brake system.

7
Transmission Oil Pressures 8000 SRM 1559

2-Speed Transmission All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1 Transmission Pump Port 2 Port 3 Port 4 Port 5 Port 6
Forward
***Low ***High Reverse Forward Torque
High Lubrication
Pressure Pressure Clutch Low Clutch Converter
Clutch
1138 1482 ±96* kPa 983 983 983 738 ±52 kPa 138 ±34.5 kPa
±96* kPa (215 ±15 psi) ±58** kPa ±58** kPa ±58** kPa (107 (20 ±5 psi)
(165 ±14 psi) (142.5 (142.5 (142.5 ±7.5 psi)
±8.5 psi) ±8.5 psi) ±8.5 psi)

*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed
manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when
the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is
equipped with a wet brake system.

8
8000 SRM 1559 Hydraulic System Relief Pressures

Hydraulic System Relief Pressures

Table 3. Hydraulic Systems With Hydraulic Gear Pump

Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 22.1 ±0.48 MPa (3205 ± 70 psi)
Secondary Relief Valve Pressure (High Idle) 15.51 ±0.48 MPa (2250 ±70 psi)

Table 4. Hydraulic Systems With Variable Displacement Pump

Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 23.7 ±0.50 MPa (3437 ± 72.5 psi)
Secondary Relief Valve Pressure (High Idle) 15.50 ±0.50 MPa (2248 ±72.5 psi)
Maximum Allowable Leakage at 1A Port to Tank 22.7 cc @ 19.3 MPa (2799 psi)

Steering System
Table 5. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (R005)

Item Quantity
Oil Temperature 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms (PSI (GM) 4.3L 12.4 ±0.3 MPa (1798 ±43.5 psi)
and Kubota 3.8L Diesel Engine)
Steering Relief Pressure at 850 rpms (Kubota 3.6L 12.4 ±0.3 MPa (1798 ±43.5 psi)
Diesel Engine)
Steering Cylinder Stroke (Each Side) 200.85 mm (7.9 in.)
Inside Steering Tire Angle 80°
Number of Turns to Lock 3.984
Turning Radius (±50 mm NO LOAD) Outside Inside
H4.0FT5 (H80FT) 2570 49
H4.0FT6 2599 49
H4.5FTS5 (H90FT) 2619 49
H4.5FT6 (H100FT) 2837 131
H5.0FT (H110FT) 2877 131
H5.5FT (H120FT) 2915 131

9
Stall Speeds (in RPM ±100 rpm) 8000 SRM 1559

Stall Speeds (in RPM ±100 rpm)

PSI (GM) 4.3L GAS
Transmission New Engine Broken-In Engine
Basic 2160 2210
DuraMatch 2160 2210
DuraMatch2 2160 2210
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid

PSI (GM) 4.3L LPG

Transmission New Engine Broken-In Engine
Basic 2070 2170
DuraMatch 2070 2170
DuraMatch2 2070 2170
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid

KUBOTA 3.6L DIESEL

Transmission New Engine Broken-In Engine
Basic 1950 2000
DuraMatch 1950 2000
DuraMatch2 1950 2000
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid

KUBOTA 3.8L DIESEL

Transmission New Engine Broken-In Engine
Basic 1900 1970
DuraMatch 1900 1970
DuraMatch2 1900 1970
DuraMatch Plus2 Stall Speed Not Valid Stall Speed Not Valid

10
1400 SRM 1245 Drive Axle Repair

General
This section has the repair procedures for the drive axle and differential assembly.

Drive Axle Repair

REMOVE AND DISASSEMBLE 13. Remove the four mounting capscrews from the
drive axle. See Figure 2.
WARNING 14. Remove blocks and lower the drive axle assembly.
When putting the lift truck on blocks, make Pull axle forward and away from frame.
sure the surface is solid, even, and level. Any
blocks used to support the lift truck must be 15. Place blocks under the differential assembly.
solid, one-piece units.
16. Remove the axle shafts, hub/brake drum assem-
1. Put blocks on each side (front and back) of the bly, and back plates. Refer to the section Brake
steering tires to prevent movement of the lift System 1800 SRM 1247.
truck.
17. Remove the capscrews and washers retaining the
2. Raise the lift truck and put blocks under the hanger assembly to the internal gear and differ-
frame so that the drive wheels do not touch the ential housing.
floor. Put blocks under the counterweight for
stability. 18. Remove the planetary gear assembly from the
differential housing.
3. Remove the mast assembly as described in the
section Mast Repairs, 2- and 3-Stage Masts
4000 SRM 1250.

4. Remove the fill plug and O-ring. Discard O-ring.

5. Remove the drain plug and O-ring to drain the

oil from the drive axle into a suitable container.
Discard O-ring. See Figure 1.

6. Remove the wheels.

7. Disconnect the brake line connecting the master

cylinder to the brake manifold located on top of
the differential housing assembly.

8. Remove the parking brake cable. Refer to the

section Brake System 1800 SRM 1247.

9. Place blocks under the axle assembly and connect

slings and lifting device.

10. Place blocks under the transmission to support

the transmission while removing the drive axle. 1. DIFFERENTIAL HOUSING ASSEMBLY
2. O-RING
11. Remove the capscrews retaining the drive shaft 3. OIL FILL PLUG
and remove the drive shaft. 4. OIL DRAIN PLUG
5. O-RING
12. Remove the transmission isolator mounting bolt
located on top of the assembly. See Figure 7. Figure 1. Drain Plug

1
Drive Axle Repair 1400 SRM 1245

Figure 2. Drive Axle

2
1400 SRM 1245 Drive Axle Repair

Legend for Figure 2

1. BRAKE MANIFOLD 14. CAPSCREW
2. INPUT SHAFT (YOKE) 15. CAPSCREW
3. OUTER SEAL 16. BRAKE ASSEMBLY
4. BEARING CONE 17. BRAKE LINE
5. BEARING CUP 18. CAPSCREW
6. INNER SEAL 19. WASHER
7. HUB/BRAKE DRUM ASSEMBLY 20. CAPSCREW
8. BEARING CUP 21. WASHER
9. BEARING CONE 22. HANGER ASSEMBLY
10. WHEEL BEARING WASHER 23. INTERNAL GEAR
11. LOCK PLATE 24. PLANETARY GEAR ASSEMBLY
12. LOCK NUT 25. SUN GEAR
13. AXLE SHAFT 26. DIFFERENTIAL HOUSING ASSEMBLY

19. Remove the internal gear from the differential

housing.
CAUTION
When removing the planetary gear, ensure that
20. Remove the sun gear from the differential hous- the needle bearings are not lost. Losing any
ing. needle bearing could result in damage to the
equipment.
21. Remove the outer snap ring retaining the ball
bearing. See Figure 3. 24. Remove pin retaining the thrust washer, plane-
tary gear, spacer, and needle bearings. See Fig-
22. Remove ball bearing. ure 4.
23. Remove inner snap ring.

1. PLANETARY GEAR ASSEMBLY

2. INNER SNAP RING
3. BALL BEARING
4. OUTER SNAP RING 1. PLANETARY GEAR ASSEMBLY
2. PIN
3. THRUST WASHER
Figure 3. Planetary Gear Disassembly/Assembly 4. SPACER
5. NEEDLE BEARINGS (QTY 48)
6. PLANETARY GEAR

Figure 4. Planetary Gear and Needle Bearings

3
Drive Axle Repair 1400 SRM 1245

25. Remove planetary gear, thrust washers, and nee- 4. Inspect the sun gear for wear or damage. If the
dle bearings from housing. sun gears show signs of wear or damage, replace
the sun gear. The splines of the sun gears must
26. Remove the 48 needle bearings (24 on each side of not be damaged.
spacer) and spacer from the planetary gear. Re-
peat this step on the remainder planetary gears. 5. Inspect the axle shafts for wear and cracks at the
flange, shaft, and splines. If axle shafts show
27. Remove the thrust washer from the inside signs of wear or damage, replace the axle shafts.
of planetary gear assembly. Repeat Step 19 The splines for the axle shafts must not be dam-
through Step 27 for the opposite side. See Fig- aged.
ure 5.
ASSEMBLE AND INSTALL
1. Install thrust washer inside the planetary gear
assembly.

2. Apply a light coat of grease on the inside of the

planetary gear and slowly install 24 needle bear-
ings on each side of the spacer into planetary gear
to be flush with the gear face.

NOTE: Spacer should split the needle bearings into

two separate sections for one planetary gear assem-
bly.

3. Apply a light coat of grease on thrust washer and

install the thrust washer on the ends of the plan-
etary gear.

1. PLANETARY GEAR ASSEMBLY 4. Install the thrust washers, planetary gear, and
2. THRUST WASHER needle bearings as an assembly into the plane-
tary gear assembly.
Figure 5. Planetary Gear Assembly and Thrust
Washer 5. Ensure flat surface of the pin is toward the center
of the carrier and install pin in alignment with
CLEAN AND INSPECT the planetary gear. Repeat Step 2 through Step 5
for remainder planetary gears.
WARNING 6. Install inner snap ring to retain pins.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using 7. Install ball bearing.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau- 8. Install outer snap ring to retain the ball bearing.
tions.
9. Install the sun gear in the differential housing.
1. Clean all the parts of the drive axle with solvent. Repeat steps Step 1 through Step 9 for the oppo-
site side.
2. Inspect the planetary gears, spacers, needle
bearings, and thrust washers for damage. If 10. Apply RTV High Performance sealant, Hyster
planetary gears, spacers, needle bearings, or Part No. 1584621 or equivalent, to the mating
thrust washers show signs of wear or damage, surface of the internal gear. Install the internal
replace the components as needed. gear on the differential housing.

3. Inspect the internal gears for wear and damage. 11. Install planetary gear assembly into the differ-
Replace as needed. Clean silicone from mating ential housing assembly.
surfaces.

4
1400 SRM 1245 Drive Axle Repair

12. Place the hanger assembly in position on the dif- 18. Install the transmission isolator mounting bolt
ferential housing assembly. Apply Loctite® 242 located on top of the assembly. Tighten the bolt to
to the capscrews and install capscrews and lock- 225 to 250 N•m (166 to 184 lbf ft). See Figure 7.
washers to retain differential housing assembly.
Tighten capscrews in sequence shown in Figure 6 19. Remove blocks from under the transmission.
to 225 to 248 N•m (166 to 183 lbf ft). Repeat
20. Install parking brake cable. Make sure the brake
steps Step 10 through Step 12 for the opposite
cable is routed properly and has no interference.
side.
Verify that the parking brake operates properly.
NOTE: Apply Loctite® 515 or High Performance RTV Refer to the section Brake System 1800 SRM
Silicone Gasket Maker on the axle shaft flange when 1247.
installing.
21. Connect the brake line connecting the master
13. Install the back plates, hub/brake drum assem- cylinder to the brake manifold located on top of
blies, and axle shafts. Refer to the section Brake the differential housing assembly.
System 1800 SRM 1247.
NOTE: When tightening the wheel nuts, DO NOT use
14. Connect slings and lifting device to drive axle. any lubricant on the studs or nuts.

NOTE: When installing the drive axle, ensure the 22. Install the wheel and nuts and tighten the nuts
drive axle is held with the upper surface of the drive to 610 to 680 N•m (450 to 502 lbf ft).
axle against the frame. This will prevent any gap be-
23. Apply multipurpose grease to new O-ring and in-
tween the frame and the drive axle mount, and will
stall O-ring on the drain plug.
ensure even weight distribution.
24. Install the O-ring and drain plug, and tighten to
15. Position the drive axle in the lift truck.
14 to 27 N•m (10 to 20 lbf ft).
NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 16.

16. Install the four mounting capscrews and wash-

ers. Tighten the capscrews to 820 to 902 N•m
(605 to 665 lbf ft).

17. Place the drive shaft in position and install the

retaining capscrews. Tighten the drive shaft cap-
screws to 50 to 66 N•m (37 to 49 lbf ft).

1. TRANSMISSION
2. DIFFERENTIAL HOUSING ASSEMBLY
3. ISOLATOR, TRANSMISSION
4. WASHER
5. LOCKWASHER
6. CAPSCREW

Figure 6. Hanger Assembly Tightening Figure 7. Transmission to Differential Housing

Sequence Assembly Mounting Bolts

5
Differential Repair 1400 SRM 1245

25. Fill the drive axle to the proper level with 7.5 to 32. Operate the lift truck and check for proper oper-
8.0 liter (7.9 to 8.4 qt) of SAE 80W-90 gear oil ation and leaks.
through the fill hole as shown in Figure 8.

26. Apply multipurpose grease to new O-ring and in-

stall O-ring on the fill plug.

27. Install the O-ring, fill plug, and tighten to 14 to

27 N•m (10 to 27 lbf ft).

28. Remove the air from the brake system as de-

scribed in the section Brake System 1800 SRM
1247.

29. Install the mast assembly as described in the sec-

tion Mast Repairs, 2- and 3-Stage Masts 4000
SRM 1250.

30. Raise the lift truck and remove blocks from under
frame and from under the counterweight. Lower 1. OIL FILL PLUG
the lift truck. 2. OIL DRAIN PLUG
3. OIL FILL LEVEL
31. Remove the blocks on each side (front and back)
of the steering tires. Figure 8. Oil Fill Level

Differential Repair
REMOVE 5. Remove brake manifold bracket.

For the following repair procedures, the drive axle 6. Remove capscrews and lockwashers retaining
must be removed and disassembled. Refer to the sec- the differential assembly support to the differ-
tion Drive Axle Repair. ential housing.

Support Differential Assembly From Using two of the M8 × 1.25 × 40 capscrews re-
Differential Housing Assembly moved from the differential assembly support,
push the differential assembly support from the
1. Remove input shaft (yoke). differential housing. If the capscrews do not have
enough threaded length, use a pry bar to finish
2. Remove the dust cover. removing the differential assembly support.
3. Remove the oil seal. See Figure 9. 7. Remove differential assembly support from the
differential housing assembly. See Figure 10.
4. Remove capscrew and lockwasher retaining
brake manifold bracket to the differential as-
sembly support. See Figure 10.

6
1400 SRM 1245 Differential Repair

1. DIFFERENTIAL HOUSING ASSEMBLY

2. OIL SEAL 1. DIFFERENTIAL HOUSING
3. DUST COVER 2. DIFFERENTIAL ASSEMBLY SUPPORT
4. INPUT SHAFT (YOKE) 3. BRAKE MANIFOLD BRACKET
4. LOCKWASHERS
Figure 9. Drive Axle Yoke 5. CAPSCREWS
6. CAPSCREW
7. LOCKWASHER

Figure 10. Differential Housing Assembly

Section Disassembly

7
Differential Repair 1400 SRM 1245

Differential Assembly From Differential Assembly Support

NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection shows
no damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the gear set
and make a record of the dimension.

NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced,
go to STEP 1. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced
in a lift truck manufactured prior to October 2006, go to STEP 2.

STEP 1.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster P/N
1581188, loosen the retainer rings. If necessary,
loosen the bearing cap capscrews to allow the re-
tainer rings to turn freely.

1. COTTER PIN
2. RETAINER RING

1. RETAINER RING SPECIAL TOOL

8
1400 SRM 1245 Differential Repair

STEP 2.
Remove differential assembly retainer ring cotter
pins. Using a retainer ring special tool, Hyster P/N
1663599, loosen the retainer rings. If necessary,
loosen the bearing cap capscrews to allow the re-
tainer rings to turn freely.

1. COTTER PIN
2. RETAINER RING

1. RETAINER RING SPECIAL TOOL

9
Differential Repair 1400 SRM 1245

STEP 3.
Remove the retainer rings.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. RETAINER RINGS

STEP 4.
Mark one differential carrier leg and bearing cap
to correctly match the parts when assembling dif-
ferential assembly support. Mark the part using a
center punch and hammer. Remove the capscrews
and washers retaining the bearing caps. Remove the
bearing caps.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. BEARINGS
3. BEARING CAPS
4. WASHERS
5. CAPSCREWS

10
1400 SRM 1245 Differential Repair

STEP 5.
Remove the differential assembly from the differen-
tial assembly support.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. TAPERED ROLLER BEARING AND CUP
3. DIFFERENTIAL ASSEMBLY

Differential Assembly Support from Drop Box

STEP 1.
Remove the capscrews and lockwashers retaining the
pinion cover plate.

Remove pinion cover plate.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. PINION COVER PLATE
3. CAPSCREWS
4. LOCKWASHERS
5. DROP BOX ASSEMBLY

11
Differential Repair 1400 SRM 1245

CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The
staked areas can cause damage to the pinion threads, making the pinion unserviceable.

NOTE: When removing the pinion, be sure to retain the shims.

STEP 2.
Use a small, flat chisel to unstake the pinion nut.

Remove the pinion nut, washer, bearing cone, and

shims.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. SHIMS
3. BEARING CONE
4. WASHER
5. PINION NUT

STEP 3.
Remove the capscrews, washers, and clamp retaining
the drop box housing.

Using two of the M8 × 1.25 × 50 capscrews removed

from the drop box housing, push the drop box housing
from the differential assembly support. If the cap-
screws do not have enough threaded length, use a pry
bar to finish removing the drop box housing.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. DROP BOX HOUSING
3. CLAMP
4. LOCKWASHERS
5. CAPSCREWS

12
1400 SRM 1245 Differential Repair

Drive Pinion and Pinion Gear, from Differential Assembly Support

NOTE: When removing the pinion, be sure to retain the shims.

STEP 1.
Carefully remove pinion assembly from the differen-
tial assembly support. Using a press and a bearing
puller, remove the shims and inner bearing from the
pinion.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. INNER BEARING
3. SHIMS
4. PINION

STEP 2.
Remove drive gear and driven gear.

1. DIFFERENTIAL ASSEMBLY SUPPORT

2. DRIVE GEAR
3. DRIVEN GEAR

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Differential Repair 1400 SRM 1245

DISASSEMBLE

Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the bearings from the differential as-
sembly.

1. BEARING CUP
2. TAPERED ROLLER BEARING
3. DIFFERENTIAL ASSEMBLY

STEP 2.
Remove the capscrews retaining the ring gear to the
differential assembly. Remove the ring gear.

1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW

14
1400 SRM 1245 Differential Repair

NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.

STEP 3.
Remove the capscrews retaining the case halves to-
gether and separate the case halves.

Inspect the case halves for wear or damage. If wear

or damage is present, the entire differential assem-
bly must be replaced.

1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF

STEP 4.
Remove the side gears and thrust washers from the
case halves.

1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF

15
Differential Repair 1400 SRM 1245

STEP 5.
Remove the spherical washers and spider gears from
the cross.

Inspect the spider gears for wear or damage. Replace

as needed.

1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS

Drop Box Housing

STEP 1.
Using a bearing puller, remove outer bearing from
the drop box housing.

1. OUTER BEARING
2. DROP BOX HOUSING

16