Chapter 8 REAR AXLE

1. Structure and Functions......................................................................... 8-1

1.1 Rear Axle in General ............................................................................................... 8-1
1.2 Structure of Each Component ................................................................................. 8-2
1.3 Steering Cylinder ..................................................................................................... 8-3
2. Removal and Installation........................................................................ 8-4
2.1 Rear Wheel and Rear Axle Assembly ..................................................................... 8-4
3. Disassembly and Reassembly............................................................... 8-7
3.1 Wheel Hub, Disassembly and Reassembly............................................................. 8-7
3.2 Knuckle (King Pin), Disassembly and Reassembly................................................. 8-9
3.3 Steering Cylinder, Disassembly and Reassembly................................................. 8-10
3.4 Tie Rod, Disassembly and Reassembly................................................................ 8-12

8
 REAR AXLE

Chapter 8 REAR AXLE

1. Structure and Functions

1.1 Rear Axle in General

Rear axle viewed

from front
(with tires installed)
5

1 C
Front of vehicle
2
Center Front of
of tire vehicle
D
E 8
6
E
3
Center
of tire
Bolt for securing A B
axle to truck

Rear axle viewed

from rear 7
4

9 F
217346

Main Components
1 Rear axle main unit 6 Right-side king pin
2 Bushing support (Rear axle support) 7 Steering cylinder
3 Wheel hub 8 Tie rod
4 Knuckle 9 Wheel bolt
5 Left-side king pin

Specifications for wheel alignment and steering angle

Truck type Truck type
Items 1 ton 2 ton 3 ton Items 1 ton 2 ton 3 ton
class class class class class class
King pin inclination angle 0° 0° 0° Distance
728 818 818
Camber angle 0° 0° 0° between king mm
(28.66) (32.20) (32.20)
pins C (in.)
Caster angle 0° 0° 0°
mm 900.5 977.5 980.5
Toe angle 0° 0° 0° Tread D
(in.) (35.453) (38.484) (38.602)
Maximum steering angle of mm 92.5 87.5 87.5
82.2° 79.1° 79.1° Stroke E
inner wheel A (in.) (3.642) (3.445) (3.445)
Maximum steering angle of 2P M14×1.5 M14×1.5 M14×1.5
57.3° 55.0° 55.0°
outer wheel B Wheel bolt size F
4P M14×1.5 M16×1.5 M16×1.5

Note: The steering angle is automatically determined by the stroke of the steering cylinder. It is not structured to be
changed by adjustment.

8-1
REAR AXLE

1.2 Structure of Each Component

4 3 16
18 14
1 2 15

12

9
11

10 17

14 13
8 Adjust with a shim so that
clearance becomes 0.2 mm
15 (0.008 in.) or less.
7
18
5 6
Detail of wheel hub Detail of king pin
214101

Main components of wheel hub

1 Spindle of knuckle 10 Hub cap
2 Oil seal 11 Left-side king pin
3 Bearing cone (inner race) 12 Thrust bearing
4 Cup (outer race) 13 Shim (for adjusting clearance)
5 Bearing cone (inner race) 14 Dust seal
6 Cup (outer race) 15 Needle bearing
7 Lock nut (hexagon nut) 16 King pin cover
8 Lock plate 17 Bolt, Nut (for securing king pin)
9 Bolt 18 Grease nipple

1 Tie rod
7
2 Tie rod pin 2 6 5
3 Dust seal
4 Bushing
5 Retainer
6 Bolt and washer assembly 3
7 Grease nipple
4
knuckle side Cylinder side
1
Detail of tie rod 214103

Filled with grease

Shim

Center of rear axle 214104

8-2
 REAR AXLE

1.3 Steering Cylinder

5 mm
4 2 (0.020 in.) thick 6 3
B 1

c c

ID d

A A

5
7 8 12

9 10 11 13 14
Detail of “A” Detail of “B”
217347

Unit: mm (in.)
Truck type
Dimension
1 ton class 2 ton class 3 ton class
ID 70 (2.76) 75 (2.95) 75 (2.95)
d 45 (1.77) 50 (1.97) 50 (1.97)
c 17 (0.67) 17 (0.67) 17 (0.67)

Main Components
1 Body 8 Snap ring
2 Header 9 Dust seal
3 Rod assembly 10 Rod seal
4 Stay rod, Nut, Washer 11 Bushing
5 Piston seal 12 O-ring
6 Guide ring 13 Snap ring
7 Bushing 14 O-ring

8-3
REAR AXLE

2. Removal and Installation

2.1 Rear Wheel and Rear Axle Assembly
Clearance Clearance
(0.8 mm (0.031 in.) or less) (0.8 mm (0.031 in.) or less)
Filled with grease
Rear axle center

Filled with grease

5
Shim adjustment

Grease nipple

4 Rear axle mounting bolt

tightening torque:
247.4 to 334.8 N·m
(25.228 to 182.473 kgf·m)
[182.473 to 246.936 lbf·ft]

6
3 1
2
214106

2.1.1 Removal of rear wheels

(1) Set the parking brake and block the front wheels.
(2) Loosen the wheel nut about two turns and raise
the rear end of the truck by using a jack or crane
at the specified point.
(a) Method using a jack
Position the jack under the counterweight at
the jacking point and raise the rear tire.
(b) Method using a crane
Attach lifting sling to the drawbar pin in the
counterweight and lift it.
(3) Remove the wheels.

When the lift truck is lifted by either method, place jack

stands under the frame to support it securely.

8-4
 REAR AXLE

2.1.2 Installation of rear wheels

To install, follow the removal sequence in reverse.
1
Note: Tighten wheel nuts evenly to the specified
torque.
6 3
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 1-3 ton class
141.2 to 172.6
Wheel nuts (14.398 to 17.600)
[104.144 to 127.303]
4 5

2
215211

2.1.3 Removal of axle assembly

Sequence
1 Wheel nut (6 places)
2 Rear wheel
3 Hose or pipe
4 Bolt
5 Rear axle (with cylinder)
6 Bushing support
Suggestions for Removal
(1) Refer to the foregoing description of "Removal of
rear wheels" to remove the rear wheels.
(2) Raise the truck with a jack and support the bottom
of both sides of the frame with jack stands.
(Approx. 500 mm (19.7 in.) is enough for the dis-
tance between the bottom of the frame and the
ground.)
(3) Disconnect the hose or pipe 3 from the cylinder
elbow (2 places). Disconnect the tire sensor har-
ness from the connector.
(4) Place a garage jack under the axle to support the
axle.
(5) Remove rear axle mounting bolts.
(6) Lower the garage jack and pull out the rear axle
(with cylinder) from the truck.

Inspections after Disassembly

(1) Bushing support
(2) Replace, if it is damaged or worn.
(3) Place the mating surface downward to replace.
(4) Apply a sufficient amount of grease to reassem-
ble.

8-5
REAR AXLE

2.1.4 Installing axle assembly

To install, follow the removal sequence in reverse.
Also follow the instructions given below.
(1) Adjust the total play, front and rear, to be 0.8 mm
(0.031 in.) or less.

CAUTION
Place the shims equally.

(2) Apply "AUTOLEX A" grease or equivalent through

grease nipple.
(3) Tighten bolts 4 to the specified torque.

8-6
 REAR AXLE

3. Disassembly and Reassembly

3.1 Wheel Hub, Disassembly and Reassembly
Sequence 7
1 Hub cap
10
2 Bolt
9
3 Lock plate 8
4 Lock nut (hexagon nut)
5 Bearing cone
5
6 Hub (with bearing cup)
7 Bearing cone
8 Oil seal 2
9 Bearing cup
10 Bearing cup
1

Suggestions for Disassembly

(1) Remove rear wheels as preparatory work.
3
(2) Check the hub for looseness. If there is loose-
ness, the bearing may be worn.
(3) If the bearing is not damaged, it is not necessary 4
6
to remove it.
(4) The cup and the cone of the bearing make a pair.
“AUTOLEX A” grease
When replacing, replace them as a set. 214107
(5) When removing the oil seal 8, replace it with a
new one. Do not reuse it.
(6) Use a special service tool to remove the bearing.

Inspections after Disassembly

(1) Bearing
Replace the bearing if damage, seizure, peel,
rotation failure or unusual noise is found.
(2) Hub
Replace the hub if cracks are detected by dye
check.
(3) Oil seal
Replace a damaged or worn oil seal with a new
one.

Suggestions for Reassembly

To reassemble, follow the disassembly sequence in
reverse, paying attention to the following points.
(1) Fill "AUTOLEX A" grease or equivalent wheel
bearing grease into the shaded area as shown in
the illustration on the right. Make sure to fill the
roller retainer with sufficient grease. Also apply
grease to the oil seal lip groove.
(2) Adjust the bearing referring to "Adjusting proce-
dure of wheel bearing reassembly" on the follow-
ing page.
(3) Fill grease in the inside of the hub cup 1 before
pushing in the hub cup 1.
8-7
REAR AXLE

Adjusting procedure of wheel bearing reassembly

(1) Apply oil or grease to the contact surface of the 3
lock nut 1 with the wheel bearing. 1
2
(2) Turn the wheel hub 3 by hand and tighten the lock
nut 1 until the turn becomes difficult. Then, loosen
the lock nut by approx. 60 degrees from that posi-
tion.
(3) Turn the rear wheel hub back and forth two to
three times in the above condition to settle the cup
and cone of the wheel bearing.
(4) Measure and record the rotation starting torque or 4
hub bolt tangential force when the preload is zero.
(5) Turn the wheel hub 3 by hand again and tighten
the lock nut 1 until the turn becomes heavy.
“AUTOLEX A” grease or
(6) Insert the tab of the lock plate 2 aligning with the equivalent wheel bearing
knuckle groove and gradually loosen the lock nut grease 214108
1 until the hole position of the lock plate 2 aligns
with the screw position of the lock nut 1. Then,
secure the lock nut 1 and lock plate 2 with two
bolts 4.
Note: Reversing the lock plate 2 changes the hole po-
sition. (See the illustration on the right.)
(7) Turn the wheel hub 3 back and forth two to three
times and make sure that the rotational driving
force or starting tangential force is within the
range shown below. If out of the range, readjust.
In case of a long-used bearing, aim a low value of
the allowance.
Unit: N (kgf) [lbf]
Truck type
Items 1 ton 2-3 ton 217348
class class
Tangential force 6.7 to 67 5.6 to 56
of hub bolt
2P (0.68 to 6.8) (0.57 to 5.7) Lock plate shape Hole of 6.5 mm
(increment from
[14.77 to 147.7] [12.35 to 123.5] (0.256 in.)
7.4 to 74 6.3 to 63 Equally spaced
when preload is
4P (0.75 to 7.5) (0.64 to 6.4)
zero) [16.31 to 163.1] [13.89 to 138.9]
Starting torque of hub
rotation (increment 0.5 to 5.0 N·m
(0.051 to 0.510 kgf·m)
from when preload is [0.369 to 3.688 lbf·ft]
zero)

Thickness of
3.2 mm (0.126 in.)
17° 214110

8-8
 REAR AXLE

3.2 Knuckle (King Pin), Disassembly and Reassembly

Suggestions for Disassembly
Start by
(1) Remove rear wheels.
(2) Remove wheel hubs.
Separation of tie rod
(1) For separation between the knuckle and the tie 1
rod, remove the bolt washer assembly 1 and 3 2
spacer 2 on the knuckle side and pull out the tie
rod pin 3.
(2) For further disassembly or a complete overhaul,
see page 10-13 for details.

214111

Removal of king pin

(1) Loosen the lock nut 1 and remove the stopper bolt
2. 4
King pin 3
(2) Remove the following parts attached to the upper Tightening torque:
part of the king pin. Remove the king pin cover 3 31 to 42 N·m
and grease nipple 4. (3 to 4 kgf·m)
[23 to 31 lbf·ft]
(3) Apply a soft metal piece to the king pin from 10
above and drive the king pin downward. Support 1
12
the king pin by hand so that it will not fall down.
2
(4) Remove the thrust bearing 10, shim 11 and
knuckle 12.
(5) Pull out the dust seal and needle bearing from the
rear axle body as necessary.
11
Inspections after Disassembly
Clean and inspect disassembled parts. Clearance: 0.2 mm (0.0079 in.) or less
ŒNeedle bearing and thrust bearing 214112
Replace the bearing if damage, seizure, peel, rotation
failure or abnormal noises are found.
ŒDust seal
Replace a damaged or worn oil seal with a new one.

Suggestions for Reassembly

To reassemble, follow the disassembly sequence in
reverse, paying attention to the following points.
(1) Reassemble the king pin inserting from the lower
side toward the upper side. (Reassembly in the
opposite direction may damage the shim 11.)
(2) Reassemble the thrust bearing 10 in the direction
as illustrated. Adjust with a shim 11 so that clear-
ance in the axial direction becomes 0.2 mm
(0.008 in.) or less.

8-9
REAR AXLE

(3) When replacing the dust seal and needle bearing,

install them in the direction and dimensions
shown in the illustration on the right using a driv-
ing tool.
Unit: N·m (kgf·m) [lbf·ft]
31 to 42
Tightening torque of lock nut (3.2 to 4.3)

140.5 mm (5.5in.)
[22.9 to 31.0]

(Seal end face)

(Bearing end face)
101mm ( 4.0in.)
(4) Place three tabs on plate 9 upward.
Align the notch to locating spring pin position pro- Reference
truded from king pin. surface
Install snuggly to the full depth.
(5) Apply a sufficient amount of grease after reas-
sembly. Apply grease until it comes out of the

(Seal end face)

(Bearing end face)

1mm (0.04in.)
boundary between the axle and the knuckle.

12mm (0.45in.)
(6) Dimensions after reassembly are shown below.

(king pin)

214113

3.3 Steering Cylinder, Disassembly and Reassembly

3.3.1 Removal of cylinder
(1) Remove cylinder mounting bolts (4 pieces) to
remove the steering cylinder. Tie rod pin

Suggestions for Removal

Start by
(1) Remove the rear axle assembly (with cylinder)
from the truck.
(2) Pull out right and left tie rod pins on the cylinder to
disconnect the knuckle from the cylinder.

Cylinder mounting bolt

(total of 4)
Tightening torque: 265 to 292 N·m
(27.0 to 29.8 kgf·m)
[195.5 to 215.4 lbf·ft] 214114

8-10
 REAR AXLE

3.3.2 Disassembly of steering cylinder

1 2 B 3 12 4

A A

11
9
14 13

5 6 7 8 10
Detail of “A” Detail of “B”

214115

Sequence
1 Stay rod, Washer and Nut 7 Bushing
2 Header 8 Snap ring
(with parts 5 through 11 assembled) 9 O-ring
3 Body 10 O-ring
4 Rod assembly 11 Piston seal
(with parts 12 through 15 assembled) 12 Guide ring
5 Dust seal 13 Snap ring
6 Rod seal 14 Bushing

Suggestions for Disassembly Suggestions for Reassembly

Make markings on 2 and 3. To reassemble, follow the disassembly sequence in
(Alignment adjustment of cylinder mounting surface) reverse, paying attention to the following points.
(1) Activate the piston by blowing compressed air (1) Conduct the reassembly work in a clean place
from the oil port to discharge oil from the inside. where no dust or abrasive foreign substance
(2) When the stay rod 1 is removed, the cylinder is enters.
divided into three parts, header 2, body 3 and rod (2) Reassemble parts while lubricating them with
assembly 4. hydraulic oil.
(3) Remove damaged or worn seals as necessary. (3) Replace seal kit parts with new ones as much as
Do not reuse removed seals. possible.
(4) Be careful not to twist O-rings when installing.

8-11
REAR AXLE

3.4 Tie Rod, Disassembly and Reassembly

4
1 2
5
3

7
214116

Sequence
1 Bolt and washer assembly 5 Retainer
2 Spacer 6 Dust seal
3 Tie rod pin 7 Bushing
4 Grease nipple

Suggestions for Disassembly

To separate the knuckle from the tie rod, remove the
bolt washer assembly 1 and spacer 2 on the knuckle
side, and pull out the tie rod pin 3.

Suggestions for Reassembly

(1) Replace damaged or worn dust seal with a new
one.
(2) Apply a sufficient amount of grease after reas-
sembly. Apply grease enough so that it comes out
of the dust seal.

8-12