SERVICE REPAIR

H800-900-1050HD, H800-900-970-1050HDS [A917]

1400 SRM 46 Description

General
This section contains description and repair procedures for the differential. There is a Specifications section
and a Troubleshooting section at the end of this section.

Description
This differential is fastened to the drive axle hous- transfers power from the pinion through the differen-
ing of the lift truck. The differential provides a sin- tial assembly to the axles. The differential assembly
gle-speed reduction for an increase in torque to the permits the drive wheels to rotate at different speeds
drive wheels. There is a housing, a ring and pinion during a turn. See Figure 1.
gear set, and the differential assembly. The ring gear

Figure 1. Typical Differential Assembly

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Differential Repair 1400 SRM 46

Legend for Figure 1

NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED.

1. PINION NUT 18. CAPSCREW OR RIVET* 34. SHIM
2. WASHER* 19. RING GEAR 35. PINION CARRIER
3. INPUT YOKE* 20. CASE HALF, FLANGE 36. COVER
4. DEFLECTOR 21. NUT* 37. BOLT
5. TRIPLE-LIP OIL SEAL 22. NUT 38. SHIFT FORK
6. DIFFERENTIAL CARRIER 23. WASHER 39. SPRING
7. FILL PLUG 24. THRUST BLOCK* 40. SHIFT SHAFT
8. ADJUSTMENT RING 25. BEARING CAP 41. PIN
9. LOCK PLATE 26. COTTER PIN (ADJUSTING 42. AIR CYLINDER TUBE
10. CAPSCREW RING)* 43. SCREW IN DIFFERENTIAL
11. SIDE GEAR 27. JAM NUT* LOCK CYLINDER
12. THRUST WASHER 28. THRUST SCREW* 44. CYLINDER COVER
13. CASE HALF 29. RETAINING RING 45. GASKET
14. BEARING CONE 30. WASHER 46. PLUG
15. BEARING CUP 31. SPIGOT BEARING 47. SHIFT COLLAR
16. PINION 32. PINION 48. PISTON
17. SPIDER 33. SPACER 49. O-RING

Differential Repair
REMOVE supported only by jacks. Jacks can slip and
fall over. Serious personal injury can result.
NOTE: The repair procedures cover all units unless
otherwise indicated. 3. Place jack stands under each spring seat of the
axle, to hold the lift truck in the raised position.
Differential Carrier From Axle Housing,
Remove
NOTE: The differential assembly can normally be
removed without removing the drive axle. On some
trucks, including the H7.00-12.50H (H150-275H),
the drive axle must be removed to remove the dif-
ferential assembly. If removal of the drive axle is
necessary, see the Drive Axle service manual for
your lift truck model.

1. Remove the mast. See the Mast section for your

lift truck model for the removal procedures.

2. Raise the end of the vehicle where the axle is

mounted. Use a jack or other lifting tool, and
place safety stands under each side of the axle.
See Figure 2.

WARNING
1. SAFETY STANDS
Block the wheels to prevent the lift truck
from moving. Support the lift truck with Figure 2. Lift Truck Support
safety stands. DO NOT work under a lift truck

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1400 SRM 46 Differential Repair

4. Remove plug from the bottom of the axle housing 8. Remove the axle shafts from the axle housing.
and drain the oil from the axle assembly. See the Drive Axle section for your model of lift
truck for the procedures.
5. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove a. On Straddle Trucks™, disconnect the drive
the speed reducer or gear box. axle universal joints at the differential
yokes. Remove the capscrews that fasten the
6. Some units have a drum or disc brake attached to bearing retainers to the differential hous-
the output yoke. Disconnect any brake linkage or ing. Pull the yoke, stub shaft and bearing
brake lines. See the Brake section for your unit. retainer from the housing.
7. Disconnect the driveline universal joint from the 9. Place a transmission jack under the differential
pinion input yoke or flange on the differential carrier for support. See Figure 4.
carrier. See Figure 3.

1. BEARING CUPS 4. WELD YOKE 7. U-JOINT CROSS

2. END YOKE 5. BEARING STRAP 8. SLIP YOKE
3. YOKE SADDLE 6. CAPSCREWS 9. TUBING

Figure 3. Typical Driveline Universal Joint

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Differential Repair 1400 SRM 46

16. Use a lifting device and lift the differential car-

rier by the input yoke or flange and place the as-
sembly on a repair stand. See Figure 5.

1. WOOD BLOCK
2. TRANSMISSION JACK
3. CAPSCREWS

Figure 4. Differential Carrier Support 1. DIFFERENTIAL CARRIER

2. REPAIR STAND
10. Remove all but the top two differential carrier
housing capscrews. See Figure 4. Figure 5. Differential Carrier Stand
11. Loosen the top two differential carrier housing Differential and Ring Gear From
capscrews and leave them attached to the assem-
bly. The capscrews will hold the differential car-
Differential Carrier, Remove
rier in the housing. NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
12. Loosen the differential carrier in the axle hous-
ure 1.
ing. Use a leather mallet to hit the mounting
flange of the differential carrier at several points. NOTE: Before working on the differential carrier, in-
spect the hypoid gear set for damage. If inspection
13. After the differential carrier is loosened, remove
shows no damage, the same gear set can be used
the top two capscrews.
again. Measure the backlash of the gear set and
make a record of the dimension. See the section Ring
CAUTION Gear Backlash, Adjust. During differential reassem-
When using a pry bar, be careful not to dam- bly, adjust the backlash to the original recorded di-
age the differential carrier or housing flange. mension when the gear set is installed into the dif-
Damage to these surfaces will cause oil leaks. ferential carrier.

14. Remove the differential carrier from the axle 1. Loosen the jam nuts on the thrust screw.
housing. Use a pry bar with a round end, to help
remove differential carrier from housing. 2. Remove the thrust screw and jam nut from the
differential carrier. See Figure 6.
15. Remove the differential carrier assembly from
under the lift truck.

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1400 SRM 46 Differential Repair

5. Remove the cotter pins that hold the bearing ad-

justing rings in position. Some differential car-
rier models have dowel pins or lock plates hold-
ing the bearing adjusting rings in position. Each
lock plate is held in position by two capscrews.
See Figure 8.

6. Remove capscrews and washers holding the two

bearing caps on the differential carrier. See Fig-
ure 8.

Figure 6. Thrust Screw and Jam Nut Removal

3. Rotate the differential carrier until the ring gear

is at the top of the assembly.

4. Mark one differential carrier leg and bearing cap

to correctly match the parts during differential
carrier assembly. Mark the parts using a center
punch and hammer. See Figure 7.

1. COTTER PIN 2. LOCK PLATE

Figure 8. Bearing Adjusting Ring Removal

7. Remove the bearing caps and bearing adjusting

rings from the differential carrier. See Figure 9.
1. BEARING CAP
2. DIFFERENTIAL CARRIER LEG
3. MATCHMARKS

Figure 7. Mark Differential Carrier Leg and

Bearing Cap

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Differential Repair 1400 SRM 46

1. Fasten a yoke or flange bar to the input yoke or

flange. When the nut is removed, the bar will
hold the drive pinion in position. See Figure 11.

2. Remove the nut and washer from the drive pin-

ion.

3. Remove the yoke or flange bar.

1. BEARING CAP
2. BEARING ADJUSTING RING

Figure 9. Bearing Cap Removal

8. Use a lifting device and lift the main differential

and ring gear assembly from the differential car-
rier. See Figure 10.

1. FLANGE BAR 2. YOKE BAR

Figure 11. Flange and Yoke Bar

CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mal-
let can damage the parts and cause driveline
runout or driveline imbalance problems after
1. BEARING CUP carrier to driveline assembly.
2. DIFFERENTIAL CARRIER
3. BEARING BORE 4. Remove the yoke or flange from the drive pinion.
4. PUT ADHESIVE HERE (INSTALLATION ONLY)
If the yoke or flange is tight on the pinion, use a
Figure 10. Main Differential and Ring Gear puller for removal. See Figure 12.
Assembly Removal
5. Remove the capscrews and washers that hold the
pinion carrier in the differential carrier. See Fig-
Drive Pinion and Pinion Carrier From
ure 13.
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.

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1400 SRM 46 Differential Repair

WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.

CAUTION
Do not use a pry bar to remove the pinion car-
rier from the carrier. A pry bar can damage the
bearing case, shims, and differential carrier.

6. Remove the drive pinion, pinion carrier, and

shims from the differential carrier. See Fig-
ure 13. If the pinion carrier is tight on the
differential carrier, hit the pinion carrier at sev-
eral points around the flange area with a leather,
plastic or rubber mallet.

7. Inspect the shims. If they are in good condition,

keep the shims together for use during differen-
tial carrier assembly.

8. If the shims are to be replaced, first measure the

total thickness of the pack. Make a note of the
A. YOKE PULLER B. FLANGE PULLER dimension. The dimension will be needed to cal-
culate the depth of the drive pinion in the differ-
Figure 12. Yoke and Flange Puller Tools ential carrier when the gear set is installed.

DISASSEMBLE
Differential and Ring Gear Assembly,
Disassemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.

NOTE: Make sure there are matching marks on the

case halves of the differential assembly. See Step 4
in the section Differential and Ring Gear From Dif-
ferential Carrier, Remove. See Figure 7.

WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
1. DRIVE PINION AND PINION CARRIER off and cause serious personal injury.
2. SHIMS
3. CAPSCREWS 1. Remove the capscrews and washers that hold
the case halves together and separate the case
Figure 13. Pinion Carrier Removal halves. If necessary, use a brass, plastic, or
leather mallet to loosen the parts.

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Differential Repair 1400 SRM 46

2. Remove the differential spider, four pinion gears, c. Press the rivets through holes in the ring
two side gears, and six thrust washers from in- gear and flange case half. Press from the
side the case halves. See Figure 14. drilled rivet head.

A. CORRECT DRILLING RIVETS FROM HEAD

B. WRONG CHISELING RIVETS FROM HEAD

Figure 15. Rivet Removal

WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
1. THRUST WASHER
2. SIDE GEAR 5. Separate the case half and ring gear using a
3. SPIDER, PINIONS, AND THRUST WASHERS press. Support the assembly under the ring gear
with metal or wood blocks and press the case
Figure 14. Ring Gear Disassembly half through the gear. See Figure 16.
3. If the ring gear needs to be replaced, remove
bolts, nuts, and washers holding the ring gear to
the flange case half.

CAUTION
Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case. See Figure 15.

4. If your differential model uses rivets to hold the

ring gear to the flange case half, remove the riv-
ets as follows:

a. Center punch each rivet head in the center,

on the ring gear side of the assembly.
1. CASE HALF 3. PLATE
b. Drill each rivet head on the ring gear side of 2. PRESS 4. SUPPORTS
the assembly to a depth equal to the thick-
ness of one rivet head. Use a drill bit that is Figure 16. Case Half and Ring Gear Separation
1/32 of an inch smaller than the body diame-
ter of the rivets. See Figure 15.

8
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1400 SRM 46 Differential Repair

6. If the differential bearings need to be replaced,

remove the bearing cones from the case halves.
Use a bearing puller or press. See Figure 17.

1. PRESS 5. SUPPORT
2. DRIVE PINION 6. SPIGOT BEARING
3. OIL SEAL 7. FLANGE SUPPORT
4. PINION CARRIER

Figure 18. Drive Pinion Disassembly

A. PULLER B. PRESS
WARNING
Figure 17. Differential Bearings Replacement
Use a brass or leather mallet for assembly and
Drive Pinion and Pinion Carrier, disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
Disassemble
off and cause serious personal injury.

WARNING NOTE: The inner bearing cone and bearing spacer

Observe all warnings and cautions provided will remain on the pinion shaft. See Figure 19.
by the press manufacturer to avoid damage to
3. If a press is not available, use a leather, plastic
components and serious personal injury.
or rubber mallet to drive the pinion through the
NOTE: Some of the parts described below are not pinion carrier.
found on some differential carrier models. See Fig-
ure 1. CAUTION
1. Place drive pinion and pinion carrier in a press. When removing the oil seal, Do not damage the
The pinion shaft must be toward the top of the wall of the bore. Damage to the bore wall can
assembly. Add supports for the pinion carrier result in oil leaks.
under the flange area. See Figure 18.
NOTE: Always replace the oil seal with a new seal
2. Press the drive pinion through the pinion carrier. during reassembly.
See Figure 18.
4. Remove the oil seal from the pinion carrier. See
Figure 19.

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Differential Repair 1400 SRM 46

6. If the spigot bearing needs to be replaced, place

the drive pinion in a vise. Install a soft metal
cover over each vise jaw to protect the drive pin-
ion.

7. Remove the snap ring from the end of the drive

pinion. See Figure 22.

NOTE: Some spigot bearings are fastened to the drive

pinion with a special peening tool. See Figure 23.

NOTE: Some spigot bearings are a two-piece assem-

bly. Remove the inner race from the pinion with a
bearing puller. Remove the outer race/roller assem-
bly from the pinion carrier with a drift or a press. See
Figure 24.

8. Remove the spigot bearing from the drive pinion

with a bearing puller.

1. DRIVE PINION
2. OIL SEAL
3. OUTER BEARING (CUP AND CONE)
4. INNER BEARING (CUP AND CONE)
5. SPIGOT BEARING
6. SNAP RING
7. BEARING SPACER

Figure 19. Drive Pinion

5. Inspect the pinion bearings and replace if neces-

sary. If the pinion bearings need to be replaced,
perform the following:

a. Remove the inner and outer bearing cups

from the inside of the cage. Use either a press
and sleeve, bearing puller, or a small drift
pin. See Figure 17 and Figure 20. If a press
is used, provide support for the pinion car-
rier under the flange area with metal or wood
blocks.

CAUTION
The puller must fit under the inner race of
the cone to remove the cone correctly without
damage.

b. Remove the inner bearing cone from the

drive pinion with a press or bearing puller. A. BEARING DRIVER B. BEARING PULLER
See Figure 21.
Figure 20. Pinion Bearing Replacement

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1400 SRM 46 Differential Repair

1. PEENING POINTS

Figure 23. Spigot Bearing Peening Points

1. PRESS 4. SUPPORTS
2. DRIVE PINION 5. INNER BEARING
3. BEARING PULLER CONE

Figure 21. Pinion Bearing Replacement

1. REMOVE OUTER RACE AND ROLLER

ASSEMBLY FROM CARRIER
2. REMOVE INNER RACE FROM PINION

Figure 24. Two-Piece Spigot Bearing

1. SPIGOT BEARING 2. SNAP RING

Figure 22. Snap Ring Removal

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Differential Repair 1400 SRM 46

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.

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.

Clean and inspect the following parts of the differen-

tial:
• Yoke- Clean the surface of the yoke journal with a
cleaning solvent and inspect the original yoke seal
surface for any grooves.
• Drive axle- Clean the parts of the axle with sol-
vent and dry with compressed air. Inspect all ma-
chined surfaces and bearings for wear and damage.
• Tapered Roller Bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
• Pinions and Gears- Inspect the pinions and gears
for wear or damage. Gears that are worn or dam-
aged must be replaced. A. DIFFERENTIAL CASE HALVES
• Axle shafts- Inspect the axle shafts for wear and B. DIFFERENTIAL GEAR NEST ASSEMBLY
cracks at the flange, shaft and splines. If axle
shafts show signs of wear or damage, replace the 1. INSPECT INSIDE SURFACES
2. PINION AND THRUST WASHER
axle shafts. 3. SIDE GEAR AND THRUST WASHER
• Main differential assembly- Inspect all parts of 4. SPIDER
the main differential assembly for wear or damage.
Parts that are damaged must be replaced. See Fig- Figure 25. Main Differential Assembly
ure 25 for parts to inspect. Inspection

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1400 SRM 46 Differential Repair

ASSEMBLE Pinion Bearings, Adjust Preload

Pinion, Bearings, and Pinion Carrier, Press Method
Assemble
WARNING
NOTE: Some of the parts described below are not Observe all warnings and cautions provided
found on some differential carrier models. See Fig- by the press manufacturer to avoid damage to
ure 1. components and serious personal injury.
1. Put differential oil on the bearings and cups. In- NOTE: If a press is not available, or the press does
stall the cups in the pinion carrier. See Figure 1. not have a pressure gauge, use the Yoke or Flange
Method to adjust pinion bearing preload.
2. Install the inner bearing and spigot bearing
against the pinion shoulders. Use a sleeve and 1. Place the drive pinion and carrier assembly in a
press to push against the inner bearing race. press with the gear head (teeth) toward the bot-
tom.
CAUTION
2. Install a sleeve of the correct size against the in-
If a new pinion is installed, a new ring gear ner race of the outer bearing. See Figure 19.
must also be installed. The pinion and ring
gear are a set (see Figure 32) and must be in- 3. Apply and hold the correct amount of pressure to
stalled together. the pinion bearings. See Specifications, Table 6.
As pressure is applied, rotate the pinion carrier
NOTE: During assembly at the factory, one spacer is several times so that the bearings make normal
used. Two thinner spacers are used if the pinion or contact.
bearings are replaced. These spacers are selected for
correct bearing preload. 4. While pressure is held against the assembly,
wrap a cord several times around the pinion
NOTE: Some spigot bearings are fastened to the pin- carrier. Fasten a Newton or pound scale to the
ion with a snap ring, and some are fastened with a cord. See Figure 26.
punch. Others can have a two-piece bearing. See Fig-
ure 24.

3. Install the spigot bearing washer and snap ring.

Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion. See Figure 19.

4. Use a press to install the outer bearing against

the spacer. Rotate the carrier to make sure the
bearings are installed correctly.

5. Use either the Press Method or the Yoke or

Flange Method, and apply the correct preload.
See Specifications, Table 6. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
1. PRESS 3. PINION BEARING
2. SLEEVE

Figure 26. Bearing Preload Check

13
Differential Repair 1400 SRM 46

5. Pull the scale to unwind the cord. Check NOTE: Use a press to install the yoke or flange.
the reading on the scale as the cord unwinds
smoothly. Do not read starting torque. Read 1. Install the input yoke or flange, nut, and washer
only the torque value after the pinion carrier on the drive pinion. The yoke or flange must
starts to rotate. The starting torque will provide be seated against the outer bearing for proper
a false reading. preload.

2. Temporarily install the drive pinion and pinion

CAUTION carrier assembly into the differential carrier. Do
On H7.00-12.50H (H150-275H) trucks, DO NOT not install shims under the pinion carrier. See
use the washer that is on the new pinion. Use Figure 34.
the thicker spacer (Hyster PN 125277). The
3. Install the pinion carrier to the differential car-
threads can be damaged or the nut can loosen
rier by installing the capscrews and tightening
if the washer is used.
them by hand. Do not install the washers, they
6. The scale reading must indicate 2.2 to 7.0 kg (5 are not required.
to 15 lb).
4. Fasten a yoke or flange bar to the input yoke or
A pinion carrier that has a 76.2 mm (3 in.) ra- flange. See Figure 11. The bar will hold the drive
dius and a 2.2 kg (5 lb) scale reading is equal pinion in position when the nut is tightened.
to 1.70 N•m (15 lbf in). Select a bearing spacer
5. Tighten the nut on the drive pinion to the correct
set for the correct preload. A thinner set will in-
torque value as shown in Specifications, Table 6.
crease the preload. A thicker bearing spacer set
Remove the yoke or flange bar.
will decrease preload.
6. Attach a torque wrench on the drive pinion nut.
7. Use the following procedure to calculate the bear-
Rotate the drive pinion and read the value indi-
ing preload (torque):
cated on the wrench. See Figure 27.
• Pounds pulled × radius (inches) = lb-in preload.
- Preload × 0.113 = N•m preload.
• Kilograms pulled × radius (cm) = kg-cm lb-in
preload
- Preload × 0.098 = N•m preload.
OR
EXAMPLES:
• Reading from spring scale = 3.4 kg (7.5 lb).
• Diameter of pinion carrier = 16.8 cm (6.62 in.).
• Radius of pinion carrier = 8.4 cm (3.31 in.).
7.5 lb × 3.31 in = 24.8 in-lb preload.
Preload × 0.113 = 2.8 N•m preload.
OR
3.4 kg × 8.4 cm = 28.6 kg-cm preload.
Preload × 0.098 = 2.8 N•m preload.

Yoke or Flange Method

WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury. Figure 27. Torque Value Reading

CAUTION 7. If the preload (torque) of pinion bearings is not

within specifications, remove the pinion and
Do not install tight fit yokes or flanges on shafts
pinion carrier from the differential carrier. Per-
using a hammer or mallet. A hammer or mallet
form Step a and Step b below, then repeat Step 1
will damage the yoke or flange.
through Step 6.

14