PROPELLER SHAFT

AND AXLE
REAR AXLE
SPECIFICATION .............................................. PA -2
TIGHTENING TORQUE ................................... PA -3
SERVICE STANDARD .................................... PA -3
ADJUSTMENT ................................................. PA -4
INSPECTION ................................................... PA -6
DIFFERENTIAL CARRIER ASSEMBLY
COMPONENTS .......................................... PA -8
REMOVAL .................................................. PA -9
DISASSEMBLY .......................................... PA -9
INSPECTION .............................................. PA -13
REASSEMBLY ........................................... PA -15
INSTALLATION .......................................... PA -21
ADJUSTMENT ........................................... PA -23

REAR AXLE
WHEEL HUB
COMPONENTS .......................................... PA -26
REPLACEMENT ........................................ PA -27

PA -2

PROPELLER SHAFT AND AXLE

REAR AXLE
SPECIFICATION

E995A950

MODEL (F320)
Description

Specification

Vehicle

HD72

Model

F320

Engine corresponded
Gear ratio
Oil spec

D4DA, D4DB, D4DD

D4AL, D4DC

5.428

6.666

Temperate or frigid zone

GL-5 SAE 85W/140

Torrid zone

GL-5 SAE 80W/90

Quantity(L)

5.3~5.7
NLGI No.2

Grease

320 x 85

Brake size(mm)
Shock absorber center distance(mm)

536

Distance of axle housing brake flange(mm)

1188

Cross section of axle housing(mm)

110 x 108

MODEL (F302)
Description

Specification

Vehicle

HD65

Model

F302

Engine corresponded

D4AL, D4DC, D4BD

6.166

Gear ratio
Quantity(L)
Oil spec

4.3~4.7

Temperate or frigid zone

GL-5 SAE 85W/140

Torrid zone

GL-5 SAE 80W/90

REAR AXLE

PA -3

TIGHTENING TORQUE
Specification
(F302)

Specification (F320)

Description
Nm

Kgf.m

lb-ft

Nm

Propeller shaft & Rear axle assembly

98~118

10~12

72~87

Wheel bolt

539~588

55~60

397~434

1.5~3

0.2~0.4

1.1~2.2

2~4

0.2~0.4

1.5~3

Torque of flange nut of pinion

380~420

38.7~42.8

280.3~309.8

330~390

Torque of binding bolt for ring gear and

differential case

240~280

24.5~28.6

177~206.5

Differential case binding bolt

130~170

13~17

96~125

50~80

Torque of differential bearing cap bolt

240~280

24.5~28.6

177~206.5

Torque of binding bolt of adjusting ring locking piece

16~30

1.6~3.1

11.8~22.1

Torque of bolt fastening the carrier and axle housing

140~180

14.3~18.3

103~133

Bolt connecting the brake backplate to

axle housing flange

98~137

10~14

72.3~101

Axle shaft bolt

110~150

11.2~15.3

81~111

Torque of binding bolt of rear axle bearing cage

140~180

14.3~18.4

103.3~132.8

Torque of oil charging and drain plugs

100~140

10.2~14.3

73.8~103.3

Binding bolt of brake tube

6~10

0.6~1

4.4~7.4

Binding bolt of 3 way connector

16~30

1.6~3.1

11.8~22.1

Torque of hard tube joint bolt

13~16

1.3~1.6

9.6~11.8

Torque of wheel hub lock nut

180~220

18.4~22.4

132.8~162.3

2~4

0.2~0.4

1.5~3

Pretightening load of pinion bearing

Pretightening load of differential bearing

Torque of lock washer bolt of wheel hub

SERVICE STANDARD
Item

Specification

Backlash of pinion and ring gear

0.15~0.3 mm

Variation of backlashes for the same pair of gears

Not greater than 0.08 mm

Oil capacity of rear axle hypoid gear

F320 : 5.5L, F302 : 4.5L

PA -4

PROPELLER SHAFT AND AXLE

ADJUSTMENT

E510DBDA

EXCHANGE THE LUBRICATING OIL

1.

Recommended lubricating oil

The rear axle gear must be applied with hypoid gear
oil SAE 80W-90 or SAE 85W-140 GL-5 Quantity: 5.5
Lit.
In tropical zone: SAE 85W-140 GL-5 for 5.5 Lit
In temperate or cold zone: SAE 80W-90 GL-5 for 5.5
Lit

2.

Time of Change of Lubricating Oil

For every 8000 Km travel,inspect the rear axle oil level
and fill as specified.
Oil change period for rear axle:

3.

1)

On completion of running at beginning of vehicle

(2500 Km of travel)

2)

Every 24000 Km of travel

Specific operation for change of lubricating oil

The rear axle oil filler plug is on the axle housing rear
cover.
The oil should be filled so that the oil level is flush with
the access hole.
NOTE
Change of Lubricating oil should be carried out in
warm condition.
Be careful not to be hurt by hot oil.
Clear the foreign matter from the oil drain plug.
Clean the health plug.

CONNECTION OF BRAKE LINE AND ABS

1.

2.

Connection of brake line

1)

Position the brake tube onto the axle housing

transition boss. Connect one end of it to the tee
fitting and the other end to brake hose.

2)

Before assembling, the line should be tested by

compressed air for any leakage and the cavity
should be cleaned.

Connection of ABS (If installed)

1)

Range of electric resistance of sensor: 15501700 ohm.

2)

When the wheel speed is greater 30 rpm, the

output induced voltage of sensor is 0.2V (AC)
and the ratio of its max induced voltage to its min
induced voltage should be 2.0.

REAR AXLE

PA -5

< If installed >

3
9

2
5

11

12
NON-ABS
2 3
1

7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

10
5

HARD PIPE ASSY-LH

3-WAY VALVE (for TRANSITION BRACKET ASSEMBLY (for ABS)
HOSE (2 for ABS)
HARD PIPE ASSY-RH
BOLT
BOLT (transition bracket assembly, for ABS)
BOLT
CLIP
WIRE HARNESS ASSEMBLY (left)
WIRE HARNESS ASSEMBLY(right)
STRAP
BREATHER PLUG
Oil filler plug
Oil drain plug
SUDPA7037L

NOTE
The brake tubes 1 and 4 should be mounted as per
the steps as given in Fig. which facilitates assembling
and sealing.

SUDPA7038L

PA -6

PROPELLER SHAFT AND AXLE

On completion of assembling of the complete axle, oil

should be applied as specified.
TEST SPECIFICATION FOR REAR AXLE
ASSEMBLY

INSPECTION
1.

For users having necessary conditions, a rear axle test

bed may be used to test the reassembled rear axle.
For users without those conditions, the rear axle may
be mounted onto the vehicle and observed during slow
running.
WARNING

Cleaning
The parts may possibly contaminated by dirty oil or
sludge. Cleaning of parts is essential. Usual methods include steam cleaning, gasoline cleaning, acid
or alkaline solution cleaning, neutral solvent cleaning,
trichloroethylene cleaning and magnetic force cleaning. Some parts may possibly be damaged during
cleaning. Therefore, careful inspection must be done
during cleaning.
1)

Metal part
a. Gasoline
Unlike any other method, gasoline is not
able to penetrate or dissolve sludge. Unless the surface of part has been precision
machined, a metal brush or other tool to remove sludge and brushing should be done
twice.
b. Alkaline treatment
Excellent result can be obtained by using
alkaline treatment to clean steel parts and
castings. Alkaline treatment is not appropriate for alloy parts.

2)

Rubber parts
Mineral oil cannot be used. Alcohol can be used
for cleaning or just a piece of clean cloth can be
used to wipe off any dirt.

3)

Corrosion prevention
After cleaning all waste oil and grease off the part
surface, a layer of clean oil should be applied on
the surface for corrosion prevention.

Observing of the operation state of the rear axle

mounted onto the vehicle should be done in a
area far away from the crowd. Pay attention to the
safety of human body and properties of other people and your own.
1.

2.

3.

Test scope
During the test, check the assembling of the rear
axle assembly for complete correctness and check
all threaded connections for correct tightening and
locking. Check the leakage condition of the bond
area and the oil seal. Check the noise of the carrier
assembly and braking effect of the wheel brake. The
test duration is not less than 3 min.
The rear axle assembly under test should conform to
the following:
1)

The gears must be free from any abnormal noise.

When one of the brake drum is applied, knocking
or drastic noise is not allowed from the differential.

2)

No rotating part may come into contact with any

stationary part.

3)

After the vehicle is stopped, when touching by

hand any bearing and oil seal seat, it should be
cool or slightly warm. The brake drum should not
be subject to overheat.

4)

No oil seal, bond area or castings blow hole, etc

may be subject to oil leakage.

A defect found in the test may be reconditioned. However, reacceptance is required after the reconditioning.

2.

EAEAEE73

Inspection
1)

Before cleaning, the part should be inspected by

using any already prepared measuring apparatus
or tool. Decide according to the specified maintenance criteria if the part is suitable for reuse. Any
damaged part should be repaired or replaced as
required. If one of paired parts is seriously worn
and the assembling clearance exceeds the specified degree, this part or the paired parts can be
replaced as required. In principle, any paired
parts should be replaced in a paired manner.

2)

For the view point of preventive maintenance,

some parts within repair or wear limit should be
replaced before they exceed the limit.

REAR AXLE
3)

3.

All parts should, as necessary, be carefully inspected by visual inspection or by means of NDT
such as infrared ray, ultrasonic wave or X ray. The
part can be repaired or replaced as necessary
if any abnormality is found during visual inspection, such as irregular wear, iron rust, bending,
deformation, scratch, crack, partial wear, discoloration, loose fitting , excessive wear of friction
liningand etc, deterioration of friction lining and
etc, failure of return spring or attenuation of return force or abnormal noise of bearing or gear,
etc.

4)

Any rubber part such as O ring, oil seal or gasket, after disassembled, should be replaced according to the situation. All hub oil seals and pinion gear oil seal after disassembled must be replaced.

5)

For cleaning of carrier and differential assembly,

replace them according to the assembling order.

6)

Check the dismounted bearing, gear and any

other parts for any ablation, flaking off, pockmark
or excessive wear. Replacement is necessary of
any such defect.

Reconditioning and Replacement

NOTE
In order to achieve effectively the value of the rear
axle product, it is an effective means to replace any
low-value wear-prone part.
For instance, replacement of any worn gasket, bush
or oil seal can prevent damage of gear or bearing, etc.
Replacement of such parts will not increase the cost
for replacement of important parts.
1)

Steel parts
For paired parts that may not be reconditioned,
such as gear, differential and bearing, when any
used or damaged part is rejected, replacement
by suited part is required as well. That is to say,
any paired parts should be replaced in a paired
manner but not in a single manner.

2)

Rubber parts
For rubber parts such as oil seal, replacement is
a must once the seal is damaged. In this case,
reuse may not be considered.

PA -7
3)

Axle housing
Any cracked or bent axle housing should be replaced at once.
CAUTION

Never try to repair any axle housing by means

of welding or straightening; otherwise, the axle
housing may become defective during use of vehicle, possibly causing serious result.

PA -8

PROPELLER SHAFT AND AXLE

DIFFERENTIAL CARRIER
ASSEMBLY
COMPONENTS

EF6A02B6

19
20

23

22 24

25

21
26
25
28
18

24
15 16 27

22

29

23
30

13
12
28

10
8

29 27

21
6
14

17

31

11

32

33

34
19

18

4
2
1

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Nut-flange
Washer
O ring
Flange assy
Oil seal assy pinion
Outer bearing-pinion
Bolt
Bearing cage
Adjusting shim
Inner bearing-pinion
Split pin
Pinion
Pilot bearing
Adjusting shim
Bolt
Bolt
Diff. carrier

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Adjusting ring
Bearing
Differential case (right)
Differential side gear shim
Bolt
Spring washer
Lock piece
Bolt
Cover
Differential side gear
Differential pinion gear shim
Differential pinion gear
Cross shaft
Ring gear
Differential case (left)
Bolt
Bolt
SUDPA7001L

DIFFERENTIAL CARRIER ASSEMBLY

REMOVAL

PA -9
DISASSEMBLY

E49F5D36

CAUTION

CAUTION

When axle shaft is dismantled, please distinguish

left from right axle shaft, thus mistake will not be
made in re-installation.

If pinion and ring gear need to be used repetitively,before Diff. Carrier assembly is decomposed, the contact dent of gear and gear gap
shall be checked. Of course, the best result is to
acquire good gear contact dent and gear gap by
adjustment. If gear is decided to replace at the
beginning, the step can be given up.

The carrier is dismantled according to the following steps

1.

EF82CD9B

Release and draw out left/right axle shaft.

THE STEPS FOR REPLACING PINION AND RING

GEAR
1.

Install Diff. Carrier shell assembly inside repair gauntry, loosen but not dismantle collar nut. Before Diff.
Carrier assembly is decomposed, mark shall be made
on the left and right bearing cover , so to prevent left
and right bearing cover from being wrongly assembled in reassembling; ditto, the adjusting ring shall
also be marked.

SUDPA7002L

2.

Support the carrier with cart, dismantle 12 bolts linking carrier and rear axle, dismantle the carrier assembly from axle housing.

printing mark

WARNING
1.
2.

Dont use hammer to knock on the edge of

axle shaft flange, dont prize axle shaft or
screw by such tools as flat spade!
Dont lie under carrier while dismantling or installing tightening bolts of carrier. Cart shall
be used to transport carrier.

SUDPA7004L

PA -10
2.

PROPELLER SHAFT AND AXLE

Dismantle the retainer bolt on the bearing cover , take

down lock piece, loosen the bolt fixing bearing cover,
dismantle nut on bearing cover by wrench; dismantle
bearing cover and bolt, take out differential assembly
from Diff. Carrier by chain and hoister.

SUDPA7005L

3.

Turn over carrier assy, make ring gear assembly upwardly, dismantle connection bolt between the bearing cage of and carrier, take down pinion assembly by
chain and hoister.

Adjusting
shim

SUDPA7006L

CAUTION
Be sure not to damage or lose the adjustment
shim on the bearing cage . If shim cannot surely
be used again, the group number and thickness
of shim shall be made clear, shim shall be reorganized and reassembly.

DIFFERENTIAL CARRIER ASSEMBLY

PA -11

DISMANTLE PINION ASSEMBLY

Adjusting shim
Pilot bearing

Pinion
Split pin
Cone & roller assy-inner
Cup-bearing-inner
Adjusting shim

Oil seal assy-pinion

Bearing cage

Flange assy
O-ring

Cup-bearing-outer

Washer
Cone & roller assy-outer

Nut-flange

Bolt

SUDPA7007L

2.

CAUTION
When dismantling flange assembly, dont lay pinion on hard surface.
1.

Take out flange nut loosened in step 1 of "The steps

for replacing pinion and ring gear" by special tool,
take down flange assembly; then press out pinion and
cone & roller assy by special tool. If bearing has
not be damaged, it is not necessary to dismantle its
cup-bearing and cone; if a part will be replaced, corresponding parts shall be replaced. (see Figure 8),
the dismantling steps are shown in 2 and 3.

Take down the cup-bearing-inner.

pressing head

pressing sleeve

pressing head
SUDPA7009L

SUDPA7008L

PA -12
3.

PROPELLER SHAFT AND AXLE

Take down the cone & roller assy-outer.

NOTE
Dismantling tools indicated in figure is only as
schematic use. Under the premise of not damaging
component, a user himself can select tools with
similar functions for dismantling.

cup-bearing
clamp

SUDPA7010L

4.

Dismantle guide bearing of pinion

SUDPA7011L

SUDPA7012L

DIFFERENTIAL CARRIER ASSEMBLY

INSPECTION

PA -13

ED66DC5F

DETECTION AND MAINTENANCE ON

DIFFERENTIAL ASSEMBLY
CONE & ROLLER ASSY
CUP-BEARIBG

Differential case (right)

Differential pinion gear
Lock piece
spring washer

bolt

bearing cap

Adjusting ring

washer

bolt
spring washer
Lock piece

Differential side gear shim

Differential side gear

Cross shaft
Differential side gear
Differential side gear shim

Ring gear

bolt

bolt

Differential case (left)

CONE & ROLLER ASSY

Adjusting ring
CUP-BEARIBG

SUDPA7013L

NOTE
-

In the process of dismantling differential assembly, differential assembly shall be laid on soft surface, so to prevent wheel tooth of ring gear from
being damaged.

PA -14
1.

PROPELLER SHAFT AND AXLE

Dismantle the linking bolt tightening ring gear and differential case, if ring gear doesn t slide down from
differential case, copper bar or soft hammer can be
used to slightly knock on the external edge of ring
gear, then dismantle ring gear.

SUDPA7014L3

4.

Dismantle differential pinion gear and cross shaft assembly, then dismantle shim and differential pinion
gear from cross shaft.

SUDPA7014L1

2.

Make assembly mark on the engagement face between left and right differential case, dismantle bolt
tightening and differential case(left and right), take
down the differential case(right).

mark
SUDPA7014L4

SUDPA7014L2

3.

5.

Take down side gear shim and side gear.

6.

Check if bearings on both ends of differential gear

have been damaged or not. If not, it is not necessary
to dismantle bearing; if damaged, the cone & roller
assy and cup-bearing shall all be replaced.

Take down side gear shim and side gear.

SUDPA7015L

DIFFERENTIAL CARRIER ASSEMBLY

REASSEMBLY

PA -15
3.

E339F5FB

ASSEMBLY ON DIFFERENTIAL ASSEMBLY

Assemble planetary gear and shim on cross shaft,

then assemble them together into differential
case(left) .
Rotate gear, check if gear system
may be blocked or not.

CAUTION
Before assembling, hyperbolic gear oil shall be
applied on the rotation engagement surface of differential case, side gear, differential pinion gear,
support shim and bearing of side gear. (in tropical
zone, applying SAE 85W-140 GL-5; in temperate
zone or Frigid zone, applying SAE 80W-90 GL-5 )
1.

Assemble the cone & roller assy.

SUDPA7016L3

4.

Assemble side gear and side gear shim.

5.

Assemble differential case(right) according to mark on

the differential case. Assemble linking bolt of differential case and tighten to correct torque. Rotate side
gear to see if gear system may be blocked or not.

SUDPA7016L1

NOTE
In order to prevent bearing from being damaged, suitable pressing sleeve shall be applied. Used cup-bearing is a good option. If the inner diameter of inner ring
is less than the outer diameter of bearing engagement
part of differential case, a notch can be made from
bearing shaft upwardly, so to solve the matter.
2.

mark

Assemble side gear shim and side gear into differential case(left).
SUDPA7016L5

SUDPA7016L-2

PA -16
6.

PROPELLER SHAFT AND AXLE

Assemble ring gear, assemble bolt linking ring gear

and differential case, tighten bolt to correct torque.

SUDPA7016L6

DIFFERENTIAL CARRIER ASSEMBLY

PA -17

ASSEMBLE AND ADJUST PINION ASSEMBLY

CUP-BEARIBG
CONE & ROLLER ASSY

Differential case (right)

spring washer
bolt
Lock piece
bearing cap
Planet gear

Adjusting ring

bolt

washer
Lock piece
spring washer
Differential side gear shim
Differential side gear
Cross shaft
Differential side gear
Differential side gear shim
Ring gear
Differential case (left)

bolt

bolt

CONE & ROLLER ASSY

CUP-BEARIBG

Adjusting ring
SUDPA7017L

CAUTION
Before pressing bearing in, a little lubricating oil
shall be applied on the out diameter of pinion.
(in tropical zone, applying SAE 85W-140 GL-5;
in temperate zone or Frigid zone, applying SAE
80W-90 GL-5 ). Before cone & roller assy of bearing and guide bearing are assembled, suitable
pressing sleeve shall be used. (size is basically
equivalent to size of inner ring of bearing, in
addition, the inner ring of pressing sleeve shall
be larger than the diameter of gear axle).

PA -18
1.

PROPELLER SHAFT AND AXLE

Assembling components of pinion assembly

1)

2.

Before assembling the cup-bearing, check if burr

exists on the surface of cup-bearing, if existing,
clear away it.
Press cup-bearing into bearing cage

Adjustment on the pre-tightened force of bearing inside pinion.

1)

pressing in

Assemble bearing cage, inside, outside bearing

and pre-tightened shim(not including pinion and
oil seal), lay pre-tightened shim between two
cone of bearing and along the direction of axis
of bearing.
CONE & ROLLER ASSY-INNER
CUP-BEARING-INNER

bearing cage

A position

cap-bearing

ADJUSTING SHIM
A position

cone-bearing
BEARING CAGE
A position cap-bearing must be assembled to position here.
Detecting the position with 0.03 feeler
Attention : Every time an cap-bearing is assembled and the
assembling is completed in one time.

CUP-BEARING-OUTER
CONE & ROLLER ASSY-OUTER
SUDPA7018L

2)

Pressing pilot bearing into pinion.

SUDPA7020L

CAUTION
If the reassembled bearing of pinion has been
used, new pre-tightened shim shall be applied.
If it is found that pre-tightened shim has been
seriously worn during the period of decomposing
assembly, the shim shall be abandoned during
the period, however, the thickness of the shim
shall be measured and recorded.

Pressing in

2)

Assembled system shall be properly oiled and lubricated; 64KN force shall be applied on assembly. Pressing sleeve must be pressed on the end
face of the inner ring of bearing.

3)

When 64KN force is applied on assembly, check

rotation torque. Around bearing cage, wind soft
metal wire, hang spring balance to pull.Rotation
torque of bearing cage shall be within the scope
of 1.5~3.0 N.m.

SUDPA7019L

CAUTION
After having confirmed value of torque, start to
rotate bearing cage.

DIFFERENTIAL CARRIER ASSEMBLY

4)

PA -19

If the pre-tightened force of bearing cannot reach

the requirement, adjust the preload of pinion
support by varying pre-tightened shim. Thicker
pre-tightened shim will reduce pre-tightened
load, thinner pre-tightened shim will increase
pre-tightened load.

2)

Press ram

Fix the bearing cage assembly by means of the

method as given in Fig.1 or 2. Jaw vice method:
Use a jaw vice to clamp the bearing saddle assembly (See Fig.1. Use flange nut to fasten the
flange. See the tightening toque table for the
tightening torque of the flange nut.)
Holding down method: By means of continuous
force, use pressing sleeve to hold down the inner
race of outer bearing.

Sleeve must apply pressure

to outer bearing cone

Spring scale

SUDPA7021L

Fig 1.

Fig 2.

NOTE
Generally, for this kind of adjustment, suitable preload
may not be acquired in one time of operation. Preload
testing shall be applied in each assembly and each
time of adjustment.
After pre-tightened force has reached requirement,
when pinion assembly is assembled, a pre-tightened
shim with size larger than test value by 0.02~0.03
shall be selected. When shim is assembled on assembly, the surplus 0.02~0.03 size can just meet the
pre-tightened pressure of assembly. Test on pre-tightened force of bearing shall be completed through 3~4
times of tests.
3.

Final test on pinion bearing for pretightening force

1)

Assemble the pinion, the bearing and the bearing

cage

SUDPA7023L

3)

Test the pinion bearing for preload.

Wind the soft annealed wire around the bearing cage. Hook up the spring balance to pull
it. The rotating torque for bearing cageshould be
between 1.5 and 3.0 N.m.
NOTE

After confirming the torque value, start the operation

of turning the bearing cage.
4)

If the requirement of bearing pretightening force

is not met, then the pinion assembly should be
disassembled and assembly and commissioning
should be done again as per the procedure
as givenin page 19 in this manual. Adjust
the preload of pinion bearing by changing the
pretightening washer. A thicker pretightening
washer will reduce the pretigthening load while
a thinner one will increase it.
WARNING

A pretightening washer as supplied by the manufacturer should be used. Never try to use a shim
or any washer as made by yourself. Such inappropriate part may cause failure of pretightening
load and bearing or gear.

SUDPA7022L

PA -20
4.

PROPELLER SHAFT AND AXLE

5.

Mounting of oil seal and flange

1)

After adjustment of the pinion bearing cage for

pretightening load, an appropriate tool should be
used to press the oil seal onto the pinion bearing
cage.

WARNING
Never use any flange whose fitting surface with
the oil seal is subject to any damage (nick or
scratch).
The surface fitting with the oil seal, on the flange, is an
important interface to prevent foreign dirt from entering into the axle and to prevent internal lubricating oil
from leaking outside. The condition of the fitting surface with the oil seal, on the flange, is a very important factor for the service life of oil seal. It is required
that oil seal fitting surface on the flange should be inspected carefully to check for any sign of abrasion or
damage. This flange should not be used in case of
any visible score or abrasion or any rubbed surface
exceeding the protecting diameter of oil seal lip.

Pressure
Pressing sleeve

Requirement and method for reassembly of flange

A
Bearing cage

Pinion
The diameter of pressing sleeve must conform to that as
shown at point A in the Figure.

Pressing sleeve

SUDPA7024L

NOTE
Oil seal

At the point A in the size of the pressing sleeve should

be ensured.
2)

Bearing cage
Pinion
Bearing

Before mounting the flange, make sure that the

fitting surface between flange and oil seal is clean
and dry. Mount the flange washer and flange nut
and tighten the flange nut to the specified torque.
Insert and lock the cotter pin. (See the toque
table for the torque.)

SUDPA7025L

NOTE
NOTE

After tightening and locking the flange nut and check

the torque of pinion bearing cage, the procedure to
mount the bearing cage assembly into the carrier may
begin.

Never use any abrasive paper or abrasive material to

clean the oil seal fitting surface on the flange. Dirt
should be got rid off by using chemical cleaning agent.
6.

Replacement of oil seal

It is strongly recommended that mounting should be
done by using an oil seal pressing sleeve. An appropriate pressing sleeve can allow the oil seal to be
mounted vertically to a proper depth.
NOTE
The oil seal may be subject to damage before and during mounting. For mounting of a new oil seal, damage
or pollution should be prevented. Before mounting the
new oil seal, the oil seal should be placed inside the
package.
A new flange should also be placed in a proper protective device before mounting.

DIFFERENTIAL CARRIER ASSEMBLY

INSTALLATION
1.

PA -21

EB8FEDFB

ASSEMBLY OF DIFFERENTIAL CARRIER

CAUTION
1.

2.

Before carrier is installed, one shall assure

the interior of axle housing has been checked
and cleared utterly
On the engagement face between axle housing and carrier, heavy load sealing glue will
be applied.

Applying glue according to the shape indicated in figure.

SUDPA7003L

1)

Install carrier assembly inside axle housing, after

bolt has been tightened, it shall be retightened.
In tightening, the torque shall reach the value
required in torque table(Table on Bolt Torque is
shown in "Tighening torque").

2)

Install axle shaft, tighten linking bolt, retighten

bolt to the scope required in torque table(Table
on Bolt Torque is shown in "Tighening torque" ).

3)

Fill wheel axle with correct lubricating oil.

CAUTION

If the pinion, ring gear, differential gear and

wheel end parts were decomposed, checked or
replaced, before traffic tool is operated, differential gear shall be assured to operate normally(in
addition, wheel on one side can rotate independently and freely).

PA -22
2.

PROPELLER SHAFT AND AXLE

Mounting of pinion assembly

1)

3.

Place the adjusting shim onto the Diff carrier. The

upper most and bottommost shims should be applied with sealant on the surface to contact the
housing.

Mounting of differential assembly

NOTE
Lubricate the differential bearing.
1)

Mount the differential assembly onto the carrier.

NOTE
If the gear before disassembly is used, the adjusting
shim kept after disassembly of the assembly should
be used. If the shims are damaged, then shims
with the same thickness and quantity should be
prepared prior to the assembling. If a new gear is to
be mounted, a set of adjusting shims with nominal
thickness can be mounted first.
That not fewer than two shims of 0.1mm and 0.2mm
should be used. (The nominal thickness of F320 series adjusting shim is 1.75mm.
2)

Mount the pinion assembly onto the carrier.

Screw on the attachment bolt to the specified
torque. (For the tightening torque see the Torque
Table.)

Adjusting shim

SUDPA7027L

2)

Mount the bearing outer races on both sides of

the differential. Mount the differential bearing cap
and adjusting ring. Mount but not tighten the attachment bolts of the bearing cap.

3)

Use hands to tighten the attachment bolts of the

bearing cap. A wrench may be used if it is difficult
to tighten the bolts by hands.
NOTE

If there is an oil groove hole, it should be aligned with that

on the carrier. The pinion assembly should be so too.
SUDPA7026L

It may be difficult to screw on the adjusting ring if the

ring and the relevant threads are not lubricated.
Up to this point, the preliminary assembling of the carrier assembly has been finished. Next, the pretightening load of the differential bearing, the backlash andcontact pattern of gears should be adjusted.

DIFFERENTIAL CARRIER ASSEMBLY

ADJUSTMENT
1.

PA -23

EA2F42D0

Adjustment of pretightening load of differential bearing

Appropriate pretightening load of differential bearing
can ensure proper operation the differential bearing
and facilitate correct contact of the pinion and ring
gear.

One pitch

NOTE
Before the adjustment, check that the adjusting ring
screw thread pair and the driven gear have been
cleaned. For adjustment of the pretightening load,
the only adjustment item is the differential adjusting
ring and any other operation has been finished in the
above-mentioned procedures.

SUDPA7030L

Tighten the left and right adjusting rings in such a

way that the axial positions of the adjusting rings on
both sides are approximately the same. Adjust the
pretightening load of the differential bearing by means
of the adjusting rings. The tightening torque to rotate
the differential assembly should be 2.0~4.0Nm.

SUDPA7031L

NOTE
When checking the pretightening load of the bearing,
the bearing must have been lubricated and checking
must be done after the bearing has rotated for several
turns.
SUDPA7028L

SUDPA7029L

PA -24
2.

PROPELLER SHAFT AND AXLE

Adjustment of backlash of gears

Rotate the left and right adjusting rings to change the
axial position of the ring gear so as to adjust the pinion
and ring gear. In order not to change the already
adjusted pretightening load of the differential bearing,
the advance and retreat amount of the left and right
adjusting rings must be equal. Measure the backlash
of the ring gear at the approximately trisection point.
Backlash should be between 0.15 and 0.30 and the
backlash variation should not be greater than 0.08.

SUDPA7032L

NOTE
In order to reduce the backlash of the gear, the adjusting ring of the ring gear on the side with tooth should
be loosened for several pitches. The adjusting ring
on the other side should be tightened for the same
pitches. Reverse operation can be carried in order to
increase the backlash.

DIFFERENTIAL CARRIER ASSEMBLY

3.

PA -25

Adjustment of contact pattern of pinion and ring gear

ADJUSTMENT OF CONTACT PATTERN OF PINION AND RING GEAR

Contact pattern of ring gear
Convex side

Concave side

Adjusting methed

Move the ring gear

towards the pinion.
If the backlash is
too small at the
moment, move the
pinion away.
SUDPA7040L1

SUDPA7040L3

SUDPA7040L5

SUDPA7040L7

SUDPA7040L2

SUDPA7040L4

SUDPA7040L6

SUDPA7040L8

SUDPA7041L

Move the ring gear

away from the
pinion.
If the backlash is
too large at the
moment, move the
pinion towards the
ring gear.

SUDPA7042L

Move the pinion

towards the ring
gear.
If the backlash is
too small at the
moment, move the
ring gear away.
SUDPA7043L

Move the pinion

away from the
ring gear.
If the backlash is
too large at the
moment, move the
ring gear towards
the pinion.

SUDPA7044L

PA -26

PROPELLER SHAFT AND AXLE

WHEEL HUB
COMPONENTS
1.

E218D6FF

Part list and exploded view of wheel end part.

5
1

6 7

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

21

22

23

13

14

15

16, 17

9
26

24, 25

REAR AXLE ASSY

SPACING RING
BRAKE ASSY-LH
BRAKE ASSY-RH
NUT
SPRING WASHER
BOLT
INNER OIL SEAL ASSY-HUB
SPACER
CUP-BEARING
CONE & ROLLER ASSY
DRUM
GEAR RING-ABS
NUT (12 for F320 series: 10 for F302 series)
HUB-RR WHEEL

NOTE

12

3, 4

8
18 19 20

10 11

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

BOLT-HUB,LH (6 for F320 series: 5 for F302 series)

BOLT-HUB,RH (6 for F320 series: 5 for F302 series)
CUP-BEARING
CONE & ROLLER ASSY
NUT
NUT
LOCK WASHER
CROSS GROOVE BOLT
OUTER OIL SEAL ASSY-HUB
AXLE SHAFT-RH
AXLE SHAFT-LH
BOLT

Never work under the vehicle when only one jack is used! During repair of the vehicle (inc. axles),
make sure the wheels are blocked by using sole timber. Make surethe vehicle will not move even if the brake fails.
SUDPA7034L

DIFFERENTIAL CARRIER ASSEMBLY

REPLACEMENT
1.

PA -27
2.

EA54727E

1)

Dismounting of wheel end part

1)

Equipment and adjustment of wheel end part

Dismounting of axle shaft

WARNING

Before dismounting the axle shaft, the wheels

should be blocked by using sole timber and the
parking system should be released.
For dismounting, loosen and screw off all the axle
shaft bolt. Use a copper hammer to slightly knock
on the center of the tail of the axle shaft for 2 or 3
times so that the axle shaft flange face is disconnected from the wheel hub joint face. Then pull
the axle shaft flange by hand and the axle shaft
can be drawn out.

Mount the brake assembly onto the flange of

axle housing and tighten the brake backplate
bolt to 98~137 N.m. Adjust the brake clearance
to 0.30.05mm (Measurement and adjustment
can be done by using a clearance gauge or
adjustment can be done on the brake pump
stroke in such a manner that the wheel hub is
blocked. Then adjust it in an inverse way for
approximately 4 to 6 turns).
NOTE

Make sure that the inside of the rear axle housing is

clean and free from any iron dust, dirt, cutting edge,
burr or any mechanical impurities.
WARNING

NOTE
When the axle shaft spline part is to pass through the
oil seal, the axle shaft lever part should be propped by
hands and the axle shaft should be rotated slowly so
that they are shift out in parallel and that hub oil seal
will not be damaged and the axle shaft are prevented
from falling onto the ground and hurting anyone.
2)

Dismounting of wheel hub

Screw off the bolt 22 and remove the locking
washer. Screw off the nut 20. Place the pallet under the wheel hub brake drum assembly. Use a
copper bar or soft hammer to knock on the outer
edge of the brake drum outwards. Remove the
wheel hub brake drum assembly.

right

left

forward

SUDPA7035L

Brakes of the same batch should be selected.

New brakes, i.e. left and right brakes, must be in
consistent color. The old brakes should be the
product on the same axle.
NOTE
During assembling, there are marks R (right) and L
(left) on the brake backplate. Make sure that assembling is not done in an inverse way.
2)

Assemble the spacing ring 2 onto the axle sleeve

so that the inner end face of the spacing ring
abuts on the sleeve step.

3)

The wheel hub with brake drum assembly must

be clean inside before mounting. The wheel hub
must be filled with No. 2 lithium grease. Mount
the spacer. Apply small amount of grease at the
internal and external cutting edges of the inner oil
seal and press in the wheel hub.

PA -28

PROPELLER SHAFT AND AXLE

Filled with
grease

SUDPA7036L

4)

Mount the wheel hub with oil seal assembly into

the axle sleeve.
Fit over the specing ring. Mount the outer bearing inner race. Screw on the wheel hub nut. At
the same time, adjust the pretightening force of
the wheel hub bearing, i.e. tighten the wheel hub
nut so that when rotating the wheel hub, the tangential pulling force applied on the wheel hub bolt
is 42-52 N. Fit over the lock washer onto the axle
sleeve. Use three cross groove screws to lock
the lock washer on the wheel hub nut and tighten
it. Mount the wheel hub outer oil seal.

3.

NOTE

2.

Assembling may fail if the thread on the axle sleeve

on the axle housing or the thread of the axle head nut
is subject to any damage or corrosion.
5)

Mount the axle shaft. Tighten the axle shaft bolt

to 18020 Nm.
NOTE

1.

2.

A proper pressing tool should be used for mounting of the oil seal. An inappropriate tool may
cause damaged oil seal.
The oil seal may be prone to damage and should
be placed in the package before assembling.

When the axle shaft splinepart is to pass through

the oil seal, the axle shaft lever part should be
propped by hands and the axle shaft should be
rotated slowly so that they pass through in parallel and that the axle shaft oil seal will not be
damaged.
CAUTION

1.

When assembling the axle assy, the lubricating oil and grease to lubricate various assemblies and parts should be of the same grade
as for normal service.
Never apply any lubricating grease onto the
bearing before assembling. (The bearing
should be lubricated when assembling.) Dry
grease may possibly prevent normal lubrication of the axle assy., even causing defective
oil seal.