Hướng dẫn tháo lắp toàn bộ phần gầm trên xe tải Hyundai

FA-4 FRONT AXLEformed 195 20Back off 22.5°1/16 tum6.9 to 11 0.7 to 1.1 M45 x 1.5M45 x 1.5M6 x 1.0M12 x 1.25 M12 x 1.25M24 X 1.5M10 x 1.25M27 x 1.5M14 x 1.5 Kingpin set bolt tightening nu

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FRONT AXLE

GENERAL FA - 2 SPECIFICATION FA - 3 SERVICE STANDARDS FA - 3 TIGHTENING TORQUE FA - 4 SPECIAL TOOL FA - 5 TROUBLESHOOTING FA - 6 SERVICE PROCEDURE FA - 7 INSPECTION AND ADJUSTMENT FA-19

Trang 2

FA-2 FRONT AXLE

Kingpin inclination and camber

Toe-in(B-A) Front of vehicle

Facilitates steering Ensures stable traveling

direction and faciliates ing

steer-Minimizes tire skidding and wear Caster

Front of vehicle

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650g120g

←

←50°

35°

650g120g

39°

←

8 X 4, 10 X 418ton cargo

29°

←

Front 1st2° ± 30´

←

←49°

SPECIFICATION

0 -2 0 -2

23ton Dump, mixer

0 -2 0 -2

A.O.H type : Air over hydraulic brake type

Remedy and remarks Limit

7° ± 30´

77

49.9-0.15-

Correct or replaceReplace

Adjust with thrust washerReplace bushing

Replace bushing

SERVICE STANDARDS

Nominal value (Basic diameter in [ ] )

Kingpin angle

Horizontal

O.D

Bushing I.D (after installation)

Wheel bearing starting torque

(standard wheel hub)

245 to 540 N·cm(25 to 55 kgf·cm)

Adjust by tangential force onwheel O.D

Standard wheel hub [8 studs]

9.5ton(Low deck)

Cargo,dump

Fullcargo

TRT,C/TRT

Trang 4

FA-4 FRONT AXLE

formed

195 (20)Back off 22.5°(1/16 tum)6.9 to 11 (0.7 to 1.1)

M45 x 1.5M45 x 1.5M6 x 1.0M12 x 1.25

M12 x 1.25M24 X 1.5M10 x 1.25M27 x 1.5M14 x 1.5

Kingpin set bolt tightening nut

Knuckle arm attaching bolt tightening nut

Tie rod arm attaching bolt tightening nut

Front brake assembly to knuckle attaching bolt tightening nut

Hub bearing lock nut locking lock bolt(Standard wheel hub)

Tie rod end tightening nut

Tie rod to tie rod arm attaching ball stud tightening nut

Wheel cover bolt

Lower cover (lower part of kingpin)

Knuckle stopper bolt

TIGHTENING TORQUE

Location tightened O.D x pitch (mm) Thread size Tightening torque N·m(kgf·m)

Primary tighteningPrimary back off

Secondary tighteningSecondary back off

Vehicle with air brake

Hub bearing lock nut

tightening

(standard wheel hub)

Chamber bracket to knuckle

attaching bolt

Wheel hub to brake drum

tightening nut

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FA-5 SPECIAL TOOL

(use with 09517-7D000 and 09517-8A000)

Installation of the inner bearing outer race(use with 09231-93100)

Installation of the inner bearing (8ton)

Installation of the inner bearing

Removal of the bearing

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FA-6 FRONT AXLE

TROUBLESHOOTING

Worn kingpinClearance between kingpin and bushing to largeSeized, worn or poorly turning wheel hub bearingWheel misalignment

Excessively worn tie rod end ball studUneven tire inflation pressure

Loose knuckle arm and tie rod arm tightening castle nutLoose tie rod ball stud tightening nut

Loose front suspension U-bolt tightening nutVertical clearance between knuckle and front axle too largeClearance between kingpin and bushing too large

Seized, worn or poorly turning thrust bearingInsufficient tire inflation pressure

Wheel misalignmentInsufficient grease on kingpinFront axle parts overtightenedWheel misalignment

Turning angle poorly adjustedBent tie rod

Different tire sizes at right and leftDifferent tire O.D.s at right and leftUneven tire pressure

Bent front axleOne of the front springs losing tension or brokenImproper wheel alignment

Different tire sizes and types at left and rightUse tires of the same size and type

Improper tire handing

ReplaceReplace kingpin bushingReplace

AdjustReplace tie rod end assemblyAdjust

Tighten to Specified torqueTighten to Specified torqueTighten to Specified torqueAdjust with kingpin thrust washerReplace kingpin bushing

Replace thrust ball bearingAdjust the tire inflation pressureAdjust

Apply greaseRetighten to specified torqueAdjust

Adjust turning angleReplace

Use tires of the same sizeUse tires of the same O.D.Adjust

ReplaceReplaceAdjustUse tire of the same size and typeAdjust

Steering wheel does

not return properly

Vehicle pulls to one

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SERVICE PROCEDURE

REMOVAL AND INSTALLATION

NOTE

1 Remove the brake hose from the frame end first and install it to

the wheel brake end first During the procedure,make also sure

that the hoses are not twisted

2 Plug the ends of the brake hose removed to prevent entry of dust

and dirt.

3 On vehicles with air over hydraulic brake, bleed the brake system

after the brake hose has been connected.

19 to 25 N·m (1.9 to 2.6 kgf·m)

Brake hose

200 to 340 N·m

(20.7 to 34.5 kgf·m)

21 to 31 N·m (2.1 to 3.2 kgf·m)

39 to 44 N·m (4.0 to 4.5 kgf·m)

Tire (8 studs wheel)

400 to 440 N·m (41 to 45 kgf·m) (10 studs wheel)

625 to 735 N·m (64 to 75 kgf·m)

Shock absorber

245 to 335 N·m (25 to 34 kgf·m)

195 to 265 N·m (20 to 27 kgf·m)

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FA-8 FRONT AXLE

WHEEL HUB AND BRAKE DRUM

Disassembly and Inspection

Standard Wheel Hub

Disassembly sequence

1 Front wheel hub cover

2 Hub cover gasket

For vehicles with air brake, all procedures are same as those for vehicles with air over

hydraulic brake except that the connection between slack adjuster and brake chamber

should be discnected at the front brake assembly.

1 2

3

4

5 6 7

8

9

10 11

12

13 14

Brake chamber

8 Oil seal

9 Hub bolt

10 Front wheel hub

11 Front brake drum

12 Front brake assembly

13 Inner bearing

14 Knuckle retainer

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Disassembly Procedure

1 Removal of lock nut

2 Removal of wheel hub and brake drum

3 Removal of inner bearing inner race and knuckle retainer

4 Install the claws of the special tool (09431-83100) in the knuckle

retainer and remove

5 Removal of inner and outer bearing outer races

Using a rod, strike with a hammer to force the outer race evenly

out from the inside notched portion

Gear Puller (09431-83100) Knuckle retainer

BS51-08B

Socket wrench

Outer race Notch

Rod

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FA-10 FRONT AXLE Reassembly

For reassembly of parts with an encircled number, see procedure given in the following

NOTE

1 When installing the brake drum to the knuckle, use care not to damage the oil

seal in the wheel hub.

2 Make sure that the brake assembly lining surfaces are free of oil or grease.

3 For vehicles with air brake, all procedures are the same as those for vehicles with

air over hydrualic brake except that the slack adjuster and brake chamber at the

front brake assembly should be connected.

7

8

9 10

11 12

13 14

Pack 120g of wheel bearing grease

<Vehicle with air over hydraulic brake>

A

Face the lip inward and apply wheel bearing grease

View “C”

22kgf·m

Wheel speed sence Spindle

Sleeve Bushing

Brake assembly Fulse ring Hub

Section B-B (Vehicle with ABS)

Reassembly sequence

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For reassembly of parts with an encircled number, see procedure given in the following

NOTE

1 When installing the brake drum to the knuckle, use care not to damage the oil

seal in the wheel hub.

2 Make sure that the brake assembly lining surfaces are free of oil or grease.

3 For vehicles with air brake, all procedures are the same as those for vehicles with

air over hydrualic brake except that the slack adjuster and brake chamber at the

front brake assembly should be connected.

Properly assemble

the shim to become

the gap 0.1 or less

<Vehicle with full air brake>

52.5±12.5kgf·m

Face the lip inward and ply wheel bearing grease

ap-Section B-B (Vehicle with ABS)

4 6

7

9 10

11 12

13 14

8

8±1.6kgf·m

14±3kgf·m

H 0.7±1.1kgf·m

2.37±0.45kgf·m 75±3kgf·m

View “H”

Wheel speed sence

Spindle

Sleeve Bushing

Brake assembly Fulse ring Hub

1.7±2.6kgf·m

6.8±10.2kgf·m

16±18kgf·m 1.6±2.4kgf·m

Keep a gap of max 1mm using 3 washers

Reassembly sequence

B C

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FA-12 FRONT AXLE

Reassembly Procedure

1 Installation of inner bearing outer race

2 Installation of outer bearing outer race

3 Installation of inner bearing inner race

NOTE:

Be sure to install the knuckle retainer.

4 Lubrication of bearing

Using a grease pump or equivalent, pack grease amply,

mak-ing sure that space between bearmak-ing rollers is filled with grease

5 Adjustment of hub bearing starting torque

(a) Install the lock washers and lock nuts and while turning the

wheel hub three times or more, tighten the lock nuts to 195

N·m (20kgf·m) Then back off fully until a gap is produced

be-tween the lock nuts and lock washers

(b) Tighten the lock nuts to 195 N·m (20 kgf·m) and then back off

22.5°(1/16 turn)

CYFA027A

Inner bearing Outer race

09231-93100

CYFA029A

09517-8A100 (8ton) 09517-7D100

Wheel Hub Bearing

Installer Bearing inner race

Press

Outer bearing Outer race

Socket wrench

09517-7D000 (8ton) 09517-8A000

09231-93100 Press

09517-7D200

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K0195D

BS51-11A

J0020B

(d) Install the lock plate and make sure that the lock nuts are all

(three) aligned with the bolt holes of the lock plate Then tighten

the lock bolts to 6.9 to 11 N·m(0.7 to 1.1 kgf·m)

If the lock nut and lock plate bolt holes are not aligned, proceed

as follows:

NOTE

1 If the tangential force is within nominal value range,

the starting torque should be as specified.

If the tangential force is out of specification, readjust

the starting torque.

2 The starting torque must not exceed the upper limit of

the nominal value.

3 Before taking measurement, make sure that the lining

is not in contact with the drum.

1 If the lock nut hole is whthin range A, loosen the lock nut and

align with hole a

2 If the lock nut hole is within range B, turn the lock plate inside

out and loosen the lock nut and align with hole a

3 If the lock nut hole is on X-X axis, turn the lock plate inside out

and the holes will be aligned

(e) Perform the same procedure as in step (b)

(f) Measurement of wheel hub bearing starting torque

Install a spring balacer to a hub bolt and pull slowly in the

tan-gential direction to measure the tantan-gential force as the wheel

hub starts to turn If the tangential force so measured is not as

specified, repeat from (c)

Lock washer 6.9 to 11 N·m (0.7 to 1.1 kgf·m)

Bolt Knuckle

(Hole position when lock plate is turned inside out)

Lock plate Lock nut

Applicable modelStandard wheel hub (8 studs)Standard wheel hub (10 studs)

Measuring positionHub bolts P.C.D 285Hub bolts P.C.D 335

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FRONT AXLE, KNUCKLE AND KINGPIN

1 Tie rod assembly

2 Tie rod arm

3 Knuckle arm

4 Set bolt

5 Kingpin cover

Chamber bracket < vehicles with air brake>

6 Gasket <Vehicles with air over hydraulic brake>

7 Kingpin lower cover

7

9

10 11

(after press fitting)

NV 50 mm Kingpin to bushing clearance

NV 0.02 to 0.06 mm

L 0.15 mm

-0.002 -0.015

+0.045 +0.018

Bend of front axle horizontal and vertical

NV 3 mm or less

L 7 mm Kingpin inclination angle

NV 7°±10´

L 7°±30´

For reassembly of parts with an encircled number, see procedure given in the following.

Knuckle to front axle clearance

NV 0.1mm or less

L 0.3 mm

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Disassembly Procedure

1 Removal of set bolt

Remove the nut and washer from the set bolt and remove the

set bolt

2 Removal of kingpin

3 Removal of kingpin bushing

After removing the plug from the spindle, remove the kingpin

bushing

NOTE

Do not reuse removed bushings (upper and lower).

4 Measurement of front axle bend

1) Put a string through the kingpin hole in the front axle and

pull it tightly(Attach a weight to each end of string)

2) Measure the bend of the front axle(vertical and horizontal)

CYFA047A

Kingpin Bushing Remover

Knuckle

Bushing

Square String

Weight Obtain the diffrence in height

Measure deviation of thread away from the centerline of hole in spring seaat surface

Hole in spring seat surface

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5 Measurement of kingpin inclination

Install the kingpin to the front axle and put the upper front axle

down on the block gauge

Measure the kingpin angle using an angle gauge

CYFA051A

Kingpin Front axle

Block gauge

Angle gauge Nominal value 7°±10´

Limit 7°±30´

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FA-17 Reassembly

For reassembly of parts with an encircled number, see procedure given in the following.

NOTE

Before inserting the kingpin, apply wheel bearing grease to front axle kingpin hole

and all through holes.

Front brake chamber

Grease used:

Wheel bearing grease [Multipurspose grease (NLGI No.2) Li soap]

88 to 102 N·m (8.8 to 10.2 kgf·m)

390 to 635 N·m (40 to 65 kgf·m)

29N·m (3 kgf·m)

105 to 165 N·m (11 to 17 kgf·m)

78 N·m (8 kgf·m)

Pack with wheel bearing grease and install with pressed side down

390 to 635 N·m (40 to 65 kgf·m) (for tightening brake assembly, knuckle and tie rod arm together

8 9

10

11 12

13

14

15 16

18

5

60 to 85 N·m (6.0 to 8.5 kgf·m)

276 to 65 N·m (27.6 to 6.5 kgf·m)

276N·m (27.6 kgf·m)

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2 Adjustment of knuckle vertical clearance

Install the kingpin and thrust bearing temporarily and turn

spindle two or three times to ensure smooth operation

Measure the clearance between the upper surface of the front

axle and knuckle Based on this value, select a kingpin thrust

washer which gives the specified clearance

Thrust washer thickness:

1 Press fit the kingpin bushing into the knuckle

At this time, one end of each bushing should be flush with the

surface “A” and the nipple holes in the knuckle should be aligned

with the oil holes in the bearing

FPV51-018

Bushing Spindle

Knuckle

Portion “A” King pin

bushing

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FA-19 INSPECTION AND ADJUSTMENT AFTER INSTALLATION

K0310C

K0136B

INSPECTION AND ADJUSTMENT AFTER

IN-STALLATION

Measure the wheel alignment and steering angle

Make sure that when making measurement, the vehicle is unloaded

kept in the horizontal position

And then confirm every port of front axle is assembled correctly

NOTE:

Before adjustment, make one more check to be sure that the

front axle is free from the following defects.

1 Loose front wheel hub

2 Loose knuckle

3 Loose connection between knuckle flange and knuckle arm

4 Loose bolts, screws and nuts.

5 Leaf spring broken or set in fatigue

6 Overinflated or underinflated tire.

7 Improperly adjusted steering gear backlash.

1 Measurement and adjustment of toe-in

1) Place the front wheels in straight ahead position

2) Make a mark on the front side of each front tire, at the

center of the tire width and height

3) Measure the heights of the needle ends of the toe-in gauge

to the same height as the marks made on the right and left

front tires, and measure the distance between the marks

4) Drive the vehicle slowly forward until the marks go round to

the rear side and reach the same height previously

sured by the toe-in gauge (180° of a tire rotation), and

mea-sure the distance between the marks on the rear side of

the tires

5) The difference between the front and rear side measurements

(dimentsion B on rear side-dimension A on front side) is the

toe-in

Front of vehicle Toe-in gauge

Center of width

Make

Center of height

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3) Wipe away grease from the end of the knuckle, and attach

the camber caster and kingpin gauge tightly against the

front wheel hub

4) Place the air bubbler of the level at the center In this

condition, read the center of the air bubble on the camber

scale to measure the camber Measure the right and left

cambers by the same procedure

3 Measurement of caster and kingpin angle

1) Obtain boards equal in height to the turning radius gauges

to hold the vehicle in a level position

2) Place the turning radius gauges in the locked state

3) Slowly drive the vehicle in the straight ahead direction until

the centers of the right and left front tires are placed at the

centers of the turntables of the right and left turning radius

gauges, and apply parking brake

NOTE:

If the vehicle is hard to move, raise it on jacks, and see

the turning radius gauges and board by the above

mentioned procedure.

With the vehicle on the jacks, take complete steps to

prevent the vehicle from moving.

4) Unlock the turning radius gauges and adjust the scales to 0°

5) Following the same procedure as for measurement of camber,

remove the hub cap, attach the camber caster and kingpin

gauge tightly against the front wheel hub, and set it at a

posi-tion where the air bubble of the level stays at the center

K0624A

Camber angle 1°± 30´

Caster angle

6) To adjust the toe, proceed as follows:

Loosen the clamp bolts on both ends of the tie rod and

place the tie rod down toward rear so that the tie rod ends

on both sides contact the ball studs at the same time Then,

turn the tie rod with a pipe wrench to obtain the specified

toe-in

After the adjustment, torque the clamp bolts to specification

2 Measurement of camber

2) Remove wheel hub caps

Kingpin inclination angle Turning radius gauge

Trang 21

8) Slowly turn the steering wheel in the reverse direction until

the scale of the turning radius gauge leaves the position

adjusted to 0° and changes its direction 20° in the left

di-rection for the right front wheel or 20° in the right didi-rection

for the left front wheel At this position, read the centers of

the air bubbles of the caster and kingpin scales to measure

the caster and kingpin angle

4 Adjustment of steering angle

NOTE

Completely finish adjustment of wheel alignment before

attempting adjustment of the steering angle.

1) Following the same procedure as for measurement of caster

and kingpin angle, set the turning radius gauges and boards

under the vehicle

2) Turn the steering wheel fully to the right or to the left

Ad-just the knuckle stopper bolt on each side so that the inside

turning angle when turned to left , is the standard angle

Caster 1°30´±30´

Kingpin inclination angle 7°±10´

INSPECTION AND ADJUSTMENT AFTER INSTALLATION

6) Depress the brake pedal to apply brakes to the front wheels

and slowly turn the steering wheel until the scale of the

turn-ing radius gauge changes its direction 20 in the right direction

for the right front wheel or 20° in the left direction for the left

front wheel, from the position adjusted to 0°

NOTE:

Without applying brakes to the front wheels, accurate

measurements cannot be made, because the tires

might slightly turn.

7) After the tires have turned 20°, rotate the adjusters to

ad-just the centers of the air bubbles of the caster and kingpin

scales to 0°

NOTE:

The kingpin scale has RIGHT and LEFT.

For the right front wheel, adjust the kingpin scale RIGHT.

For the left front wheel, adjust the kingpin scale LEFT.

Caster angle

BS51-17D

Kingpin inclination angle Turning radius gauge

FNT51-044

Knuckle stopper bolt

0 -2

0 -2 0 -2

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K0626A

5 Measurement of side slip

NOTE

Completely finish adjustment of wheel alignment before

measurement of side slip.

2) While maintaining the front wheels in straight ahead position,

drive over the slip tester as slowly as possible

NOTE

Make sure that the side tester is completely passed with

the wheels in straight ahead position Do not allow the

wheels to steer or fall down from the sides of taster.

3) The value indicated by the tester is the side slip If the side

slip is over 3 mm for 1mm readjustment of wheel alignment

is necessary

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REAR AXLE

GENERAL RA - 2 SPECIFICATION RA - 3 SERVICE STANDARDS RA - 5 TIGHTENING TORQUE RA - 7 SPECIAL TOOLS RA - 9 TROUBLESHOOTING RA-11 SERVICE PROCEDURE RA-12

Trang 24

RA-2 REAR AXLE

GENERAL

Standard differential

The rear axle is a final reduction equipment consisting of final

re-duction gear and differential gear installed as a single unit The

final reduction gear reduces the rotating speed transmitted from

the engine to deliver a larger torque wheel the differential adjusts

the different amounts between the outer and inner wheels are made

to rotate when the vehicle rounds a corner

The reduction gear changes the direction of transmission output

rotation(drive force) by 90 degrees and distributes it to the drive

wheels While the vehicle is running straight, the differential pinion

does not turn on the spider but turns with the differential case When

the vehicle makes a turn, the outer wheel turns faster than the inner

wheel and as a result, the inner wheel is decelerated while the outer

wheel is accelerated to cope with this, the differential pinion, while

turning on its spider, revolve round the larger resistance differential

gear, thereby driving the other differential gear to perform differential

action In this manner, tire drag and resultant wear are prevented

No-spin differential

When the vehicle is driving a right turn, the right hand(inner) wheel

side driven clutch remains in complete mesh with the spider clutch

teeth to transmit the torque, In this state, the same rotation speed

as the ring gear is transmitted to the right hand (inner) wheel to

drive the vehicle forward On the left hand (outer) wheel side,

however, due to the frictional force from the road, the driven clutch

is lifted by the center cam slope and leaves the spider (clutch teeth

disengaged) so that the left hand wheel is driven at a higher speed

than the right hand wheel, allowing the vehicle to make a turn

Differential pinion Differentialgear

Reduction pinion

Reduction gear

Spider

J0753A BS52-02A

J0116B

No-spin differential state of a right turn

Driven clutch and spider are in engagement and hence turn

at the same speed

Spider clutch teeth drive driven clutch teeth

Driven clutch is lifted off from spider clutch teeth by center cam teeth and turns faster

Cutaway view of a no-spin differential LH driven clutch

is disengaged from spider and turn faster

Riders on center cam teeth

Spider Driven clutch Spider and RH driven clutch turn

at same speed

Drvien clutch teeth are driven by spider

Differential case

Center cam Driven clutch

Trang 25

RA-3 SPECIFICATIONS

SPECIFICATIONS

D6BRD6BRD6DA22D6DA19D6AVD6ABD6CA/ D6ACD8AYD6CAD8AYD6ACD6ACD6ABD6ACD8AYD6CAD6CAD8AYD6ACD6ABD6ACD6AB

D6CAD8AYD8AYD6AC

D8AX

D6CAD6ACD6CAD6ACD6CA

DUMPCARGODUMP

CARGO

TRT

CARGO

CARGOPULL CARGO

DUMP

CARGO

Short/Medium (wheel base)Cargo Medium (wheel base)Extra Long (wheel base)

CARGO

MIX

TRTTRT

TRT

CARGOCARGODUMPMIX

16TON

11.5TON16TON6m3

54TON70TON

90TON

19TON19.5TON23TON

D10HD10HD10HD10HD10HD10HD12HD12HD10HTD10HTD10HTD10HTD10HTD12HTD10HTD10HTT14HTD10HTD10HTD10HTD10HTD10HT

D10HTD10HTD10HTD12HTR178HTD12HTD12HTD12HTD12HTD12HTD12HTD12HT

6,6665,5715,5716,1666,1664,3334,8755,5715,1436,1665,1435,5716,1666,1666,6665,1435,5716,1665,5716,1665,1435,571

5,5716,6666,1665,5714,8753,9094,3333,6676,1664,8755,5715,143

Trang 26

RA-4 REAR AXLE

D12HT12

17

D10HT10

11.5

D14HT10

Full floatingSingle reductionHypoid gearStraight level gear

Oil Quantity (Fill the reservoir to the plug hole)

D10H10

-D4HT6.5

Trang 27

RA-5 SERVICE STANDARDS

0.25 to 0.330.30 to 0.41

0.15 or less

200 to 300 N·cm(20 to 30 kgf·cm)

250 to 350 N·cm(25 to 35 kgf·cm)

160 to 240 N·cm(16 to 24 kgf·cm)

200 to 280 N·cm(20 to 28 kgf·cm)

0.19 to 0.250.20 to 0.280.25 to 0.45(ø26) 0.17 to 0.28(ø26) 0.17 to 0.28(ø26) 0.17 to 0.28

SERVICE STANDARDS

Nominal value (Basic diameter in [ ])

Adjust by shim and adjustingscrew

Adjust side bearing or checktightening of ger bolts

27 to 38 N (2.8 to 3.9 kgf)D12H, D12HT

25 to 34N (2.5 to 3.5 kgf)D10H, D10HT

22 to 30N (2.2 to 3.1 kgf)D12H, D12HT

17 to 24N (1.7 to 2.4 kgf)Replace thrust washer

Replace friction side

Limit Remedy and remarks Maintenance item

Backlash between

reduction gear and

re-duction pinion

D4H,D4HTD10H,D10HTD12H,D12HT

D4H,D4HT

D10H,D10HTD12H,D12HTR178HT

D4H,D4HT

D10H,D10HTD12H,D12HTR178HT

D4H,D4HTD10H,D10HTD12H,D12HTD4H,D4HTD10H,D10HTD12H,D12HT

Runout of reduction gear back

0.6

0.2

-0.50.80.80.50.50.5

stalledbearing

Trang 28

Rein-RA-6 REAR AXLE

0.5

2.01.0-

4

L2-L1=2.50.50.52.0

Overall starting torque of

inter-differen-tial ( All gears in mesh)

Companion flange radial play

Radial play of bearing in

inter-differen-tial section

Inter-differential inner gear to drive

heli-cal gear spline play in turning direction

Backlash of inter-differential gear

Inter-differential pinion gear to spider

clearance

Inter-differential case bushing to inter

gear clearance

Shift fork to lock clutch groove clearance

Bend of through shaft

Sharting torque of drive helical gear

Nominal value (Basic diameter in [ ]) Limit Remedy and remarks Maintenance item

• Adjust by adjusting screw

• Tangential force on tial case periphery

differen-D4H,D4HT,D10H,D10HT

23 to 32N (2.3 to 3.3kgf)D12H, D12HT

21 to 29 N (2.1 to 3.0 kgf)Tangential force at bolt hole ofvompanion flange

135 to 175 N(14.1 to 17.9 kgf) <P12>

120 to 150 N (12.2 to 15.6 kgf)

<spicer #1710, #1810>Adjust helical gear bearingstarting torque

70 to 98N (7.1 to 10 kgf)Replace

ReplaceReplaceReplaceReplace

Differential

(Rear 1st

axle)

200 to 300 N·cm(20 to 30 kgf·cm)

250 to 350 N·cm(25 to 35 kgf·cm)

1080 to 1370 N·cm(110 to 140 kgf·cm)

-0.19 to 0.25[26] 0.17 to 0.27

[70] 0.07 to 0.19

1.2 to 1.40.6 or less

245 to 345 N·cm(25 to 35 kgf·cm)

0

L2-L1=2.50.07 to 0.220.051.0 or less

D4H,D4HT

D10H,D10HTD12H,D12HT

Differential side bearing

starting torque

Bend of rear axle housing (before installation)

Bend of rear axle housing (after installation)

Rear axle

shaft

Play at splines in rotating direction

Wrap of flange (Surface runout)

Bend of shaft

Trang 29

Tightening torque (kgf·m)

TIGHTENING TORQUE

R4R10R12

R4MountingDrum mounting nut

R4R10,R12Except 4 x 2D4HD10H, D12HR178HTD4G, D4HTD10HD10HT,D12H,D12HTR178HTD4HD10H, D10HTD12H, D12HTR178HTD4H, D4HTD10H,D10HTD12H, D12HTR178HTD4H, D4HTD10H, D10HTD12H,D12HTR178HTD4H, D4HT,D10H,D10HT,D12H,D12HTR178HTD4HD10H, D12HR178HTR4R10,R12

Hub bearing lock nut(22.5° or 1/16 turn back offafter tightening)

Lock boltWhen hub to rear axle shaft

Wheel hub to brakeAnchor bracket bolt

0.7-1.11123.7-3.1732.810.513.811.5-17.520-3655-7575-9530406241-47102035-4719-238.01219.517.0-20.816.645.55039-433-4

0.8-1.812.52117-215.0-7.010-12

M65 x 2.0M85 x 2.0M90 x 2.0M6 x 1.0M12 x 1.25M16 x 1.5M22 x 1.5M12 x 1.25M14 x 1.5M14 x 1.5M27 x 1.5M33 x 15

M14 x 1.5M10 x 1.0M20 x 1.5

M12 x 1.25M14 x 1.5M16 x 1.5

M16 x 1.5M22 x 1.5M24 x 1.5

M10 x 1.25

M12 x 1.25M14 x 1.5M16 x 1.5M18 x 1.5M20 x 1.5

Spring seat nut

Reduction pinion companion flange castle nut

Reduction gear differential case mounting bolt

Differential case bolt

Differential carrier to reduction pinion bearing

retainer mounting bolt

Bearing cap mounting bolt

Adjusting screw lock pawl bolt

Rear axle housing to differential carrier

mounting bolt

Drain plug oil filler plug

Trang 30

RA-8 REAR AXLE

O.D x pitch (mm)

Tightening torque (kgf·m)

55-75

55-758108

16.645.55039-433.2-3.9

20-3655-75

8.012.019.512.52117-21

1 or more5-7.50.43-48

M33 x 1.5

M33 x 1.5M12 x 1.25M12 x 1.25M12 x 1.25

M16 x 1.5M22 x 1.5M24 x 1.5

M10 x 1.25

M27 x 1.5M33 x 1.5

M12 x 1.25M14 x 1.25M16 x 1.5M12 x 1.25M14 x 1.5M16 x 1.5M12 x 1.25M12 x 1.25M3 x 0.5M12 x 1.25M12 x 1.25

Rear 1st axle

Lock out cylinder

Inter-differential outer case tocompanion flange mounting castle nutReduction pinion castle nut

Differential carrier to carrier cover mounting boltInter-axle differential case mounting bolt

Carrier cover and inter-axle differentialassembly mounting bolt

Bearing cap bolt

Through shaft rear endstopper bolt lock nut

Through shaftcompanion flangemounting castle nutReduction pinionbearing retainermounting boltRear axle housing todifferential carriermounting boltRod and piston mounting nutShaft fork set bolt

Cover screwLock and cylinder to housing mounting boltLock out cylinder to deferential cylinder mounting bolt

D4HTD10 HTD12HTR178HTTurn down stopper bolt byhand until it bottoms, back off1/4 turn, and lock with nut

D4HTD10HT,D12HT

D4HTD10HTD12HT, R178HTD4HT

D10HT,D12HTR178HT

Trang 31

RA-9 SPECIAL TOOL

Bearing outer race installer

Installation of the bearing outer race(use with 09533-7A100, 09533-7A200,09533-7H000, 09533-87100)

Installation of the bearing outer race(use with 09231-93100)

Removal and installation of the wheel ing lock nut

bear-Installation of the front bearing outer race(use with 09231-93100)

Installation of the rear bearing outer raceand front outer race

(use with 09231-93100)

Trang 32

RA-10 REAR AXLE

09533-7H000

Installation of the retainer bearing oil seal09527-7A000

Oil seal installer

Side bearing installer

Installation of the rear bearing outer race(use with 09231-93100)

Installation of the side bearing

Installation of the bearing oil seal

Installation of the side bearing

Removal of the bearing and gear

Installation of the pinion bearing09533-7A000

Pinion bearing installer

D337A00A

Trang 33

AdjustReplace

Adjust oil levelReplace

RetightenRecoat sealantReplace carrierassemblyRetighenReplaceReplaceReplace

ReplaceAdjust

Overfilled gear oilWorn or damaged oil seal

Loose reduction and differential assembly mounting boltsFaulty sealant

Cracked or damaged differential carrier

Loose rear axle shaft mounting boltWorn or damaged oil seal

Cracked, damaged or clogged air breatherBroken rear axle shaft

Rear axle shaft disconnected

Damaged or seized reduction gear or reduction pinion

Damaged or seized differential gear or differential pinionReduction gear backlash too large

Differential gear backlash too large

Low reduction pinion starting torqueLoose reduction pinion lock nut

Loose reduction gear and differential case tightening boltsNoise from propeller shaft

Worn or damaged reduction gear or reduction pinion

Poorly adjusted reduction gear backlash or tooth contactSeized, worn or badly turning side bearing

Seized, worn or badly turning inner orouter bearing of reduction pinionImproperly adjusted side bearing preloadSeized, worn or badly turning wheel hub bearing

Adjust (if meshing

is bad after justment, replacedifferentialgear set)

ad-Continuousnoise whiledriving

Oil leak Oil leak from

companionflange

Oil leak fromdifferentialcarrier and rearaxle housing

Oil leak fromrear axleshaft

Propellershaft turnsbut vehicledoes not move

Faulty power

transmission

Noise producedwhen starting

or whenshifting gear

Remedy Probable cause

Symptom

Replace reductiongear set

Tighten tospecified torque

Replace reductiongear set

Trang 34

RA-12 REAR AXLE

Damaged wheel hub bearingDamaged side bearingDamaged reduction pinion inner bearing outer bearingDamaged differential gear, differential pinion

Worn, damaged differential gear washerDamaged reduction gear, reduction pinionLoose differential carrier assembly attaching nutsWorn, damaged reduction gear, differential pinionWorn, damaged differential gear, differential pinionWorn, damaged differential gear washer

Seized, worn, poorly turning side bearingDamaged, seized driven clutch and spider center camassembly (no-spin differential)

Deteriorated spring(no-spin differential)

Replace reductiongear setRetighten

RetightenReplace reduction gear setReplace

ReplaceReplace

Repace

NOTE

* In the case of vehicles with no-spin differential, clicking noise is generate but this is not abnormal.

REMOVAL AND INSTALLATION

1 Draining of differential oil

1) Rear axle and rear 2nd axle

2) Forward rear axle

M18x1.5M20x1.5

5 to 7kgf·m

10 to 12kgf·m

Trang 35

RA-13 SERVICE PROCEDURE

2 Removal and installation for rear single-axle vehicles

NOTE

1 Remove the brake hose from the frame end first and install it to the axle end

first During the procedure, make sure that the hose is not twisted.

2 Plug the end of the brake hose removed to prevent entry of dust and dirt.

3 On vehicles with air over hydraulic brake, bleed the brake system of air after the

brake hose has been connected.

U-bolt and shock absorber

21 to 314 N·m (2.1 to 3.2 kgf·m)

69 to 74 N·m (7.0 to 7.5 kgf·m)

7.8 to 9.8 N·m (0.8 to 1.0 kgf·m)

115 to 175 N·m (P10, P11)

Fluid pipe

Trang 36

RA-14 REAR AXLE

3 Removal and installation for rear double-axle vehicles

NOTE

1 Remove the brake hose from the frame end first and install it to the axle end

first During the procedure, make sure that the hose is not twisted.

2 Plug the end of the brake hose removed to prevent entry of dust and dirt.

3 On vehicles with air over hydraulic brake, bleed the brake system of air after the

brake hose has been connected.

19 to 25 N·m (1.9 to 2.6 kgf·m)

NOTE

Remove the air hose

from the frame end first

and install it to the lockout

cylinder end first.

Make sure that the hose

is not twisted during the

Radius rod

225 to 265 N·m (23 to 27 kgf·m)

Brake hose

69 to 74 N·m (7.0 to 7.5 kgf·m)

39 to 44 N·m (4.0 to 4.5 kgf·m)

21 to 31 N·m (2.1 to 3.2 kgf·m)

225 to

265 N·m (23 to

27 kgf·m)

Trang 37

RA-15 SERVICE PROCEDURE

WHEEL HUB AND BRAKE DRUM

Standard wheel hub

Disassembly sequence

1 Rear axle shaft

2 Outer oil seal

3 Lock bolt

4 Hub bearing lock plate

5 Hub bearing nut

6 Outer bearing

7 Hub bolt

8 Rear wheel hub

9 Rear brake drum

10 Oil seal

11 Inner bearing

12 Oil seal retainer

For disassembly of parts with an encircled number, see procedure given in the following.

Wear, damage of lip Rotation

Wear, damage

by rotation Corrosion

9

10 11 12

Trang 38

RA-16 REAR AXLE

J0081F

J0052B

Disassembly

1 Removal of rear axle shaft

Remove all bolts attaching the shaft

Then, remove the shaft by screwing evenly two of the removed

bolts into the bolt holes provided in the flange for disassembly

purpose

2 Removal of outer oil seal

Remove the outer oil seal holding the out side projection of the

oil seal with a plier

3 Remove of lock nut

4 Removal of rear wheel hub

5 Removal of inner bearing inner race and oil seal retainer

09517-7A000 (D12) 09517-7H000(D10) 09517-88200 (D08)

Wheel Hub Puller

Washer

Gear puller (09431-83100)

Adapter

Oil seal retainer

JCW50026

JCW50027

Trang 39

420 N·m(43 kgf·m)

(Face the lip inward

and apply grease.

Take care not to

damage the oil seal

When removing the

rear axle shaft)

Pack 1150 of wheel bearing grease

(Face the lip inward and apply grease)

After tightening, stake at four points

295 N·m (30 kgf·m)

270 N·m (27.7kgf·m)

135 N·m (13.8 kgf·m)

< FV, FS>

145 to 185N·m (15 to 19 kgf·m)

1 2

6 Removal of inner and outer bearing race

Using a bar at three notches on inside of hub, strike with a

hammer to force out evenly

NOTE:

Remove squarely to prevent damage to the oil seal.

For reassembly of parts with an encircled number, see procedure given in the following.

Tighten the specified torque (1.9 to 2.6 kgf·m) after air bleeding

Trang 40

RA-18 REAR AXLE

Reassembly sequence

11 → 13 → 12 → 6 → 5 → 4 → 3 → 14 → 2→ 1

9 →10→ 8 → 7

2 Full air brake vehicles

For reassembly of parts with an encircled number, see procedure given in the following.

420 N·m (43 kgf·m)

(Face the lip inward

and apply grease.

Take care not to

damage the oil seal

When removing the

rear axle shaft)

(Face the lip inward and apply grease)

After tightening, stake at four points

295 N·m (30 kgf·m)

1

2 3 4 5

6

7 8

13 14

Định dạng
Số trang	80
Dung lượng	1,22 MB