Hyundai HD78 Propeller Shaft and Axle (Мост и Редуктор)

Propeller Shaft and
Axle
General
Specification .................................................
Troubleshooting ............................................
Generals .......................................................
Adjustment ....................................................
Rear Axle(F302,F320)
PA -2
PA -6
PA -10
PA -11
Propeller Shaft
Components .................................................
Removal .......................................................
Inspection .....................................................
Front Propeller Shaft
Disassembly ............................................
Inspection ................................................
Reassembly ............................................
Rear Propeller Shaft
Disassembly ............................................
Inspection ................................................
Reassembly ............................................
Installation ...............................................
PA -12
PA -13
PA -13
PA -15
PA -16
PA -18
PA
PA
PA
PA
-20
-21
-23
-24
Front Axle
Wheel Hub
Disassembly ............................................
Inspection ................................................
Reassembly ............................................
Axle and Knuckle
Components ............................................
Disassembly ............................................
Reassembly ............................................
Wheel Alignment
Description ..............................................
Inspection ................................................
PA -25
PA -30
PA -30
PA -36
PA -37
PA -40
PA -44
PA -44
Rear Axle
Wheel Hub
Components ............................................
Removal ..................................................
Disassembly ............................................
Inspection ................................................
Reassembly ............................................
Axle Housing
Components ............................................
Disassembly ............................................
Reassembly ............................................
PA -49
PA -50
PA- 52
PA -53
PA -53
PA -57
PA -58
PA -60
Adjustment ....................................................
Inspection .....................................................
Specification .................................................
Wheel Hub
Components ............................................
Replacement ...........................................
Differential Carrier Assembly
Components ............................................
Removal ..................................................
Installation ...............................................
Disassembly ............................................
Inspection ................................................
Reassembly ............................................
Adjustment ..............................................
PA -63
PA -65
PA -67
PA -69
PA -70
PA
PA
PA
PA
PA
PA
PA
-72
-73
-73
-74
-78
-80
-85
PA
PA
PA
PA
PA
-88
-89
-90
-91
-93

Components .................................................
Removal .......................................................
Installation ....................................................
Disassembly .................................................
Reassembly ..................................................
General
Specification
Propeller Shaft
Item
Specification
Type
P2
P3
DS3000
Outer Diameter Thickness
63.52.6
88.93
88.93
Spider Outer Diameter
18.3
22.7
22.7
Bearing Cap Outer Diameter
30
35
35
Outer Diameter
2.5
2.65
2.65
Length
12.3
19.4
19.4
Amount
26
30
30
Spline Diameter
38.7
38.7
38.7
Inner Diameter Outer Diameter
3572
4080
4080
Pipe
Universal Joint
Needle roller Bearing
Slip Joint
Center Bearing
Unit : mm
Front Axle
Model
Item
HD65
HD72
HD78
1680
1475
1667
Camber
130
Caster
23030
810
Toe In (mm)
1~3
1~3
King Pin Offset (mm)
26.87
26.87
17.10
King Pin Span (mm)
1508
1318
Inside
44.1~44.3
36~38
44.3~44.5
Outside
33.3~33.5
27~29
30~32
115
115
127
Tread (mm)
King Pin Tilting Angle
Steering Angle()
Wheel Offset(mm)
Rear Axle
Item
Reduction
Specification
Type
D2H, D3H, D033H, R130HS
Gear Shape
Hypoid Gear
Reduction Ratio
R130HS : R3.727
D033H : R3.417 / R3.727
Differential
Gear Shape
Straight Bevel Gear
Gear Oil
Type
API GL-5, SAE 80W/90
Injection Amount
6.20.25
Type
MS511-33, WBG-2
Injection Amount
330g at each
Hub Grease
(Left/Right)
Service Standard
Propeller Shaft
Item
Reference Value
Propeller Shaft Run-out
Clearance of Spline
Limit Value
0.4
0.1 or less
0.01~0.09
0.3
Front
5g/3000rpm
Rear
10g/3000rpm
Clearance between Spider and Needle Bearing
0.02~0.05
0.1
Clearance of Snap Ring to axis
0.06 or less
Unbalance of Propeller Shaft
Rotational Direction
0.6
Remedy and Remark

Repair or replace
Replace
Adjust Balance Weight
Replace with spider kit

Adjust Snap Ring
Unit : mm
Front Axle
Item
Reference Value
(STD Diameter is in [])
Limit Value
Remedy and Remark
A=122.91
A=126
King Pin Outer Diameter
29.947~29.98
Bushing Inner Diameter

(After pressed-in)
28~28.033
0.020~0.086
0.15
Replace the bushing
0.02~0.1
0.2
Adjust with Shim

Shim thickness: 0.10, 0.15, 0.
20, 0.30
Clearance between King pin

and Bushing
Vertical clearance of knuckle
Front Wheel Hub Starting Torque (kgfcm)
0.98~3.45 Nm (10~35kgfcm, 0.73~2.55 Ib-ft)
Repair or replace
Replace
Adjust
Rear Axle
Item
Rear Axle Shaft
Reference Value
Limit Value
0.03
0.05
0.05~0.15
0.5
Bending of shaft center

Bending of flange surface
Clearance between differential gear and rear axle shaft spline portion
Backlash between the differential gear and pinion
0.18 ~0.23
0.5
Backlash between the final drive gear and the final drive pinion
0.2 ~ 0.28
Run-out of the back surface the final drive gear
0.05 or less
0.05
D2H,D3H
Final drive pinion
Starting torque(kgf
D033H
m)
0.1 ~ 0.2
Starting torque of Rear wheel hub(kgf.m)
0.2 ~ 0.4
Remedy and Remark

Replace
Replace
Adjust by differential gear spacer (when the tooth of differential
gear is damaged, replace the differential gear).
Adjust
Replace the carrier assembly
Adjust (do not install the outer
oil seal)
0.2 ~ 0.3
-
Adjust (do not install the outer

oil seal and axle shaft)
0.5 or less
Repair or replace
B1 - B2
1.0 or less
Replace
Tightening Torque
Propeller Shaft
Install Position
Tightening Torque
Nm
kgfm
Ib.f-ft
Nut for tightening the flange yoke to the propeller shaft flange
98~107.8
10~11
72.3~79.5
Lock nut for tightening the companion

flange
539.3~608
55~62
397.8~448.4
Center bearing bolt tightening
93.1~102.9
9.5~10.5
68.7~75.9
Front Axle
Tightening Torque
Install Position
Nm
Kgfm
Ib.f-ft
196~294
20~30
144.6~216.9
Tightening Nut for King pin Lock pin
28~38
2.9~3.9
20.9~28.2
Tightening Nut for Shock Absorber
13~17
1.3~1.7
9.4~12.2
Tightening Bolt for Brake Backing Plate
98~137
10~14
72.3~101.2
Tightening Nut for Hub bolt
539~588
55~60
397.8~433.9
98~127
10~13
72.3~94.0
58
43.3
Tightening Nut for Knuckle Arm
Tightening the wheel hub lock nut
1st tightening torque

2nd tightening torque
after full loosening
Loosening angle after
tightening
Approximately 45 <1/8 turns>
Rear Axle
Install Position
Tightening Torque
Nm
Kgfm
Ib.f-ft
226~265
23~27
166.3~195.2
Tightening bolt for bearing cap
69~78
7~8
50.6~57.8
Bolt (for install the side bearing lock plate)
20~26
2.0~2.7
14.4~19.5
Tightening Nut for differential carrier assembly
34~44
3.5~4.5
25.3~32.5
Tightening Bolt for rear brake assembly
98~137
10~14
72.3~101.2
Nut (for install the wheel hub and the rear drum brake):After tightening, lock using a triangular or pyramid punch
304~382
31~39
224.2~282.0
Tighten the wheel bearing 1st tightening

lock nut
2nd tightening torque after full
loosening
98~127
10~13
72.3~94
29~39
3~4
21.6~28.9
Tightening Bolt for rear axle shaft
98~117
10~12
72.3~86.7
Filler plug
59~78
6~8
43.3~57.8
Drain plug
59~78
6~8
43.3~57.8
Bolt (for install the final drive gear and the differential case)
Troubleshooting
Propeller Shaft
Symptom
Vibration at Propeller Shaft
High Speed
Causes
The yoke direction is wrong.
Remedy
Rearrange the align mark.
The universal joint needle roller bearing is defective. Replace with the spider kit.
The propeller shaft is bent
Replace the propeller shaft.
The dynamic balance of the propeller shaft is incorrAdjust the dynamic balance.
ect.
Low Speed
The flange linking bolt is loosened.
Tighten with specified torque.
The ball bearing is worn out or adhered.
Replace the ball bearing.
The transmission is too fast.
Move the shift bar of the transmission to proper position.
The axial clearance of the universal joint spider is toAdjust the clearance by Shim.
o large.
AbnormalNoise
at Propeller Shaft
At start
The clearance of the slip joint spline is too large.
Replace the yoke sleeve or propeller shaft.
The flange linking blot is loosened.
The tightening bolt for center bearing is loosened.
The center bearing is weakened or deformed.
Replace the rubber
The universal joint needle roller bearing is worn.
Replace with the spider kit.
The clearance of the slip joint spline is too large.
Replace the yoke sleeve or propeller shaft.
Running with R- The axial clearance of the universal joint spider is toAdjust the clearance by Shim.
egular speed o large.
The universal joint needle roller bearing is worn.
Replace with the spider kit.
The ball bearing is worn out or adhered.
Replace the ball bearing.
The lubricant between the bearing and the spline is

Lubricate.
defective.
Front Axle
Symptom
Vibration at Steering Wheel
Causes
Kingpin wear.
Remedy
Replace.
The clearance of kingpin and bushing is too large. Replace the kingpin bushing.
The front wheel hub bearing is adhered, worn or dReplace.
efective in rotation.
The wheel alignment is defective.
Adjust
The tie rod end ball stud is too worn out.
Replace the tie rod end assembly.
The air pressures of the tires are uneven.
Adjust.
The tightening castle nuts for the knuckle arm and

Tighten with the specified torque.
the tie rod arm are loosened.
The tightening nut for tie rod ball stud is loosened. Tighten with the specified torque.
The tightening nut for suspension U-bolt is loosenTighten with the specified torque.
ed.
The vertical clearance between the knuckle and tAdjust the kingpin thrust washer.
he front axle is too large.
Hard to control the steering The clearance between the kingpin and the kingpiReplace the kingpin bushing.
wheel
n bushing is too large.
The strut ball bearing is adhered, worn or defectivReplace the thrust ball bearing.
e in rotation.
The tire air pressure is too low.
Adjust the air pressure.
Adjust.
The grease is deficiency in kingpin.
Oil the grease.
Steering wheel does not ret- The front axle parts are too tightened.
urn properly.
Tighten with the specified torque.
Steering wheel can not be t- The rotating angle adjustment is defective.

urned.
The tie rod is bent.
Adjust the rotating angle.
Vehicle is drawn to one side. The sizes of the left and right tires are different.
Replace with the same size.
Adjust.
Replace.
The outer diameters of the left and right tires are

Replace with the same size.
different.
The air pressures of the tires are different.
Apply the same air pressure.
The front axle is bent.
Replace.
The front spring is damaged or its tension is defecReplace.

tive.
Front tire is worn irregularly The wheel alignment is defective.
Adjust.
or too early.
The sizes or types of the left and right tires are difReplace with the same size and type.
ferent.
The tire is not managed properly.
Replace the tire position.
Rear Axle
EMTPA5001A-A
General Information
EMTPA5002A-A
Generals
EMTPA5003A
The propeller shaft installing between the transmission

and the rear axle transmits the engine force changed by
the transmission to the final gear of the rear axle. The
propeller shaft comprises of the front and the rear
propeller shafts. Two or more parts are linked and
supported by wheel base. The propeller shaft having two
or more parts includes a center bearing at the center
portion supported by the frame.
EMTPA5004A
The relative position of the transmission to the rear axle

is varying in accordance with the condition of the road
surface, the vibration during running of the vehicle and
the amount of the load. To compensate the varying of the
position, the propeller shaft includes the universal joint
and the slip joint.
Propeller Shaft Run-out

1. Install a dial gauge at the body of the center portion
of the front propeller shaft.
2. With rotating the front shaft slowly, check the run-out.
And then, check the other side propeller shaft also.
Item
Run-out Spec.(mm)
0.4 or less
0.4 or less
EMTPA5005A
Adjustment
Universal Joint and Boot
1. Set the transmission to the neutral position or the N.
2. Lift up the vehicle.
3. Check that the center bearing moves excessively or
makes an abnormal noise. If there is any problem,
replace the propeller shaft.
KMTPA5003A
4. Check that the universal joint boot is torn or shocked.

If there is any problem, replace the propeller shaft.
5. Check that the universal joint moves excessively or
makes an abnormal noise. If there is any problem,
replace the propeller shaft.
KMTPA101A
3. If the run-out of the propeller shaft excesses the

specifications, replace the propeller shaft.
Propeller Shaft
Components
SUDPAA004L
1. Front Propeller Shaft

2. Rear Propeller Shaft Support
3. Rear Propeller Shaft
4. Rear Axle
Removal
1. Making an align mark (C) to the flange yoke (A) of the
front propeller shaft and the parking brake drum (B),
remove the tightening nut (D) of the propeller shaft.
3. Making an align mark (C) to the rear axle companion

flange (A) and the flange yoke (B) of the rear
propeller shaft, remove the tightening bolt (D) of the
propeller shaft.
KMTPA113A
KMTPA111A
2. Remove the tightening bolt (A) of the center bearing

bracket.
NOTICE
For the short wheel base, the center bearing is one,
while for the long wheel base, the center bearings
are two.
Inspection
1. After checking the clearance between the spider and
the needle roller bearing, if it excesses the
specifications, replace the spider kit.
Clearance between the Spider and the Needle Roller:
0.01~0.06mm
EMTPA5007A
KMTPA112A
2. Measuring the bending at the 50mm around the

welding center portion of the propeller shaft, if it
excesses the specification, replace the propeller
shaft.
Limit value : 0.4mm or less
EMTPA5008A

Disassembly
SUDPAA005L
Disassembling Sequence
. Snap Ring
. Needle Roller Bearing
3. Flange Yoke
4. Universal Joint Spider
5. Self Locking Nut
6. Companion Package
* For disassembly for the number, refer to the
corresponding contents.
7. Holder
8. Hanger
9. Cushion
10. Oil Seal Kit(Housing and Oil Seal)
11. Packing
. Ball Bearing
13. Front Propeller Shaft
1. Remove the snap ring
EMTPA5012A
CAUTION
Replace the snap ring with new ones after
removal.
Inspection
1. Check the clearance between the spider and the
needle roller bearing.
CAUTION
When replace the spider or needle roller
bearing, replace them with the spider kit.
EMTPA5010A
2. Remove the needle roller bearing.

EMTPA5007A
2. Check the clearance of snap ring along to the axis

direction
1. Measure the clearance
2. Adjust the clearance
CAUTION
removal.
Use the snap rings having

thickness at the both sides.
the
EMTPA5011A
3. Remove the ball bearing
KMTAX5009A
same
Snap Ring
Thickness
Color Code
1.5
No Color
1.55
Yellow
1.6
Blue
1.66
Cyan
EMTPA5013A
3. Measure the bending at the bent center portion of the

propeller shaft.
EMTPA5008A
Reassembly
EMTPA5014A
1. Insert the needle roller bearing by pressing-in.
EMTPA5015A
2. Install the snap ring.
EMTPA5017A
4. Using a thickness gauge, measure the gap between

the snap ring and the groove of the snap ring.
Reference : 0~0.15mm
Limit : 0.3mm or less
CAUTION
If the gap excesses the limit value, replace
the snap ring.
EMTPA5016A
3. Assemble the center bearing.

Setting the arrow mark to upward, insert the center
bearing into cushion, and apply adhesion into the
gap. Install the housing tightening bolt with setting it's
head to upward.
EMTPA5030A
5. Apply the grease enough to the grease nipple of the

universal joint.
Recommended Grease: SELL ALVANIA EP #2

Disassembly
SUDPAA006L
Disassembly Sequence
. Snap Ring
3. Front Yoke
5. Packing Retainer
6. Shield Packing
8. Sleeve Yoke
For disassembly for the number, refer to the corresponding contents.
1. Remove the snap ring.
CAUTION
Do not reuse the snap ring.
EMTPA5007A
2. Check the clearance of snap ring along to the axis.

1. Measure the clearance.
EMTPA5010A
2. Remove the needle roller bearing.
2. Adjust the clearance.

CAUTION
removal.
Use the snap rings having the same

thickness at the both sides.
EMTPA5011A
Inspection
1. Check the clearance between the spider needle roller
bearings.
CAUTION
When replace the spider or needle roller
bearing, replace them with the spider kit.
KMTAX5009A
Snap Ring
Thickness
Color Code
1.5
No Color
1.55
Yellow
1.6
Blue
1.65
Cyan
4. Check the clearance of spline
EMTPA5013A
3. Check the bending of the propeller shaft.

EMTPA5020A
EMTPA5008A
EMTPA5021A
EMTPA5019A
Reassembly
SUDPAA007L
. Snap Ring
3. Flange Yoke
5. Packing Retainer
6. Sheild Packing
8. Sleeve Yoke
For assembly for the number, refer to the corresponding contents.
1. Insert the needle roller bearing by pressing-in.
EMTPA5011A
2. Install the snap ring.
EMTPA5016A
Installation
1. Setting the aligning mark (C) of the rear axle
companion flange (A) to that of the flange yoke (B) of
the rear propeller shaft, tighten the bolt (D) of the
propeller shaft.
Tightening Torque :
98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft) : P3
59~69 Nm (6~7 kgf.m, 43.3~50.6 lb-ft) : P2
NOTICE
For narrow version, the center bearing is one, while
for the wide version, the center bearings are two.
3. Setting the aligning mark (C) of the flange yoke (A) of
the front propeller shaft to that of the parking brake
drum (B), tighten the bolt (D) of the propeller shaft.
Tightening Torque :
98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft)
KMTPA113A
2. Install the tightening bolt (A) of the center bearing

bracket.
Tightening Torque :
69~93 Nm (7~9.5 kgf.m, 50.6~68.7 lb-ft)
KMTPA111A
4. After filling up the recommended grease to the

grease nipple (A) until it leaks out from the oil seal,
wipe out the leaked grease completely.
Recommended Grease: ALVANIA EP #2
KMTPA112A
KMTPA114A
Front Axle
Wheel Hub
Disassembly
SUDPAA008L
Disassembly Sequence
1. Hub Cap
2. Split Pin
3. Lock Nut
4. Washer
5. Wheel Hub and Brake Drum
6. Hub Bolt
7. Front Brake Drum
8. Front Wheel Hub
9. Outer Bearing Inner Race
10. Spacer
11. Oil Seal
12. Inner Bearing Inner Race

13. Inner Bearing Outer Race
14. Outer Bearing Outer Race
15. Dust Cover
16. Front Brake Assembly
1. Place the wooden block (A) at the front and rear side
of the rear wheel.
3. After removing the wheel nut (A), remove the wheel

and tire (B) from the hub (C).
CAUTION
When removing the wheel and tire (B), be careful
that the hub bolt (D) is not damaged.
KMTPA201A
2. Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (C).
KMTPA203A
4. After removing the wheel cap(A), remove the split pin

(B) and the lock nut (C).
CAUTION
When removing the lock nut (C), be careful that
the washer and the outer bearing does not fall
down to the ground.
KMTPA202A
KMTPA204A
5. Remove the washer (A), the outer bearing (B) and

the hub assembly (C) from the knuckle (D).
7. Tapping evenly the three notch parts on the other

side hub inner surface with a brass bar, removing the
outer bearing race (A).
KMTPA205A
6. Tapping evenly the three notch parts on the hub inner

surface with a brass bar, removing the oil seal (A),
the inner bearing (B) and the inner bearing race (C).
KMTPA207A
8. After removing the hub nut (A), remove the drum (C)
from the wheel hub (B).
NOTICE
When using the brass bar, do not tap except the
notch parts (A) located inside of the hub.
KMTPA208A
KMTPA206A
[Disk Brake]
SUDPAA009L
Disassembling Sequence
1. Hub Cap
2. Split Pin
3. Lock Nut
4. Washer
5. Disk Brake Assembly
6. Wheel Hub and Rotor

7. Bolt
8. Rotor
9. Front Wheel Hub
10. Hub Bolt
11. Outer Bearing Inner Race
12. Oil Seal

13. Inner Bearing Inner Race
14. Inner Bearing Outer Race
15. Outer Bearing Outer Race
16. Adaptor
17. Dust Cover
1. Place the wooden block (A) at the front and rear

sides of the rear wheel.
3. After removing the wheel nut (A), remove the wheel

CAUTION
When removing the wheel and tire, be careful
that the hub bolt is not damaged.
KMTPA201A
2. Loosen the wheel nut (A). Lift up the axle using a

garage jack (B) and support the frame with a safety
stand (C).
KMTPA203A
4. After removing the grease cap (A), remove the split

pin (B) and the lock nut (C).
KMTPS5990A
KMTPA202A
5. Remove the washer (D), the outer bearing (E) and

the hub assembly (F) from the knuckle (G).
6. After taking off the disk tightening bolt, remove the
disk assembly from the wheel hub (B).
7. Remove the hub from the knuckle.
Inspection
1. Check the cracks and wear on the hub.
2. Check the scratch and damage on the brake disk.
3. Check for the cracks.
4. Check the assembling state of the bearing.
Reassembly
[Drum Brake]
1. Installing the drum (C) at the wheel hub (B), tighten
the hub nut (A).
Tightening Torque:
304~382 Nm (31~39 kgfm, 224~282 lb-ft)
CAUTION
After tightening the hub nut (A), at least 4
portions of the groove parts of the stud should
be calked.
KMTPA209A
3. Install the inner bearing (B) and the oil seal (C) at the
wheel hub (A).
CAUTION
The bearing should be a set with the bearing
race.
Use a new oil seal (C) always.
KMTPA208A
2. By tapping evenly, install the inner bearing race (B)

and the outer bearing race (C) at the wheel hub (A).
KMTPA210A
4. Fill the recommended grease in the wheel hub (A)

with specified amount.
Recommended Grease:
MS511-33
5. Install the washer (A), the outer bearing (B) and the
hub assembly (C) at the knuckle (D).
CAUTION
race.
KMTPA211A
7. Just before the wheel hub (A) is moving, measure the

tangential force using a spring gauge (B). Calculate
the moving torque by multiplying the tangential force
to the radius.
Moving Torque:
0.98~3.4 Nm (0.10~0.35 kgfm, 0.72~2.51 lb-ft)
KMTPA205A
6. Install the lock nut (A).

1) With rotating the hub assembly (B), tighten the
lock nut (A) fully with the force of 98~117
Nm(10~13 kgfm, 72.3~86.7 lb-ft) After that,
loosen the nut fully.
2) Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 5~9 Nm (6
kgfm, 43.3 lb-ft) and then loosen the nut at
45(1/8 turns).
KMTPA212A
8. After installing the split pin (B), install the wheel cap
(A).
10.After removing the garage jack (B) supporting the

axle and the safety stand (C) supporting the frame,
tighten the wheel nut (A) with the specified torque.
Tightening Torque :
539~588 Nm (55~60 kgfm, 397.8~433.9 lb-ft)
KMTPA213A
9. After installing the wheel and tire (B) to the hub (C),
tighten the wheel nut (A).
KMTPA202A
11.Remove the wooden block (A) from the front and rear
KMTPA203A
KMTPA201A
[Disk Brake]
1. Installing the disk assembly (A) to the wheel hub (B),
tighten the disk tightening bolt (C).
Tightening Torque:
57~60 Nm (5.8~6.1 kgfm, 42~44 lb-ft)

Recommended Grease:
MS511-33
6. Install the washer, the outer bearing and the hub
assembly at the knuckle.
CAUTION
race.
1. With rotating the hub assembly (B), tighten the
lock nut (A) fully with the force of 98~117
Nm(10~13 kgfm, 72.3~86.7 lb-ft) After that,
loosen the nut fully.
2. Again with rotating the hub assembly (B), tighten
the lock nut (A) with the force of 59 Nm (6 kgfm,
3.31 lb-ft) and then loosen the nut at 45(1/8
turns).
KISE220E
2. Tighten the hub nut to the hub assembly.

CAUTION
After tightening the hub nut, at least 4 portions
of the groove parts of the stud should be calked.
3. By tapping evenly, install the inner bearing race (C)
and the outer bearing race (E) at the wheel hub (D).
4. Install the inner bearing (B) and the oil seal (A) at the
wheel hub (D).
CAUTION
race.
Replace the oil seal(A) with new one after

removal.
KISE210E
KMTPA5002A

the moving torque by multiplying the tangential force
to the radius.
10.After installing the wheel and tire (B) to the hub (C),
Starting Torque : 0.98~3.4 Nm (0.10~0.35 kgfm,

0.72~2.5 lb-ft)
KMTPA5508A
11.After removing the garage jack (B) supporting the

axle and the safety stand (C) supporting the frame,
tighten the wheel nut (A) with the specified torque.
Tightening Torque : 539~588 Nm (55~60 kgfm,
397.8~433.9 lb-ft)
KMTPA212A
9. After installing the split pin (A), install the wheel cap.
KMTPS5991A
KMTPA202A
KMTPA201A
Axle And Knuckle

Components
SUDPAA001L
1. Hub Cap
2. Front Wheel Hub
3. Knuckle
4. Dust Cap
5. Kingpin Shim
6. Kingpin
7. Thrust Bearing
8. Drag Link
9. Knuckle Arm
10. Tie Rod
11. Front Axle
KMTPA302A
Disassembly
[Drum Type]
1. Remove the wheel hub. (Refer to the Wheel Hub
Disassembly)
4. After taking off the split pin (A) of the tie rod
tightening bolt and the lock nut (B), remove the tie
rod (C).
2. After taking off the tightening bolt (A) for brake

assembly, remove the brake assembly (B) from the
knuckle (C).
NOTICE
Tie the brake assembly (B) around the relating parts
with a wire.
KMTPA303A
5. After taking off the lock pin nut (A) and the washer
(B), remove the lock pin (C).
KMTPA301A
3. After taking off the split pin (A) of the drag link
tightening bolt and lock nut (B), remove the drag link
(C).
KMTPA304A
6. After taking off the dust cap (A), remove the king pin
(B).
[Disk Type]
1. Remove the wheel hub. (Refer to the Wheel Hub
Disassembly)
2. After holding the brake hose with a vise pliers, loosen
the brake hose tightening bolt (A). Remove the brake
hose.
KMTPA305A
7. Remove the king pin shim (A) and the dust seal (B).
KMTBR5536A
3. After taking off the tightening bolt(A) of the brake

caliper, remove the caliper(B).
KMTPA306A
SUDPAA002L
4. After taking off the tightening bolt of the dust cover,

remove the dust cover from the knuckle.
5. After taking off the split pin (A) of the drag link
tightening bolt and the lock nut (B), remove the drag
link (C).
7. After taking off the lock pin nut (A) and the washer
(B), remove the lock pin (C).
KMTPA304A
KMTPA302A
6. After taking off the split pin (A) of the tie rod
tightening bolt and the lock nut (B), remove the tie
rod (C).
8. After removing the dust cap (A), remove the king pin
(B).
KMTPA305A
KMTPA303A
9. Remove the king pin bushing (A) and the dust seal
(B).
2. Install the king pin (B) and then, install the dust cap
(A).
CAUTION
The groove portion of the king pin (B) should
face to inside.
KMTPA306A
Reassembly
[Drum Type]
KMTPA305A
1. Install the king pin bushing (A) and the dust seal (B).
3. After installing the lock pin (C), install the lock pin
washer (B) and nut (A).
Tightening Torque :
28~38 Nm (2.9~3.9 kgfm, 21~28 lb-ft)
KMTPA306A
KMTPA304A
4. After installing the tie rod (C), install the lock nut (B)
and split pin (A).
Tightening Torque :
69~118 Nm (7~12 kgfm, 51~87 lb-ft)
6. After install the brake assembly (B) to the knuckle

(C), install the tightening bolt (A) for the brake
assembly.
Tightening Torque :
98~137 Nm (10~14 kgfm, 72~101 lb-ft)
KMTPA303A
5. After installing the drag link (C), install the lock nut
(B) and split pin (A).
Tightening Torque :
196~294 Nm (20~30 kgfm, 145~217 lb-ft)
KMTPA301A
7. Install the wheel hub. (Refer to the Wheel Hub

Assembly)
[Disk Type]
1. Install the king pin bushing (A) and the dust seal (B).
KMTPA302A
KMTPA306A
2. Install the king pin (B) and then, install the dust cap
(A).
CAUTION
The groove portion of the king pin (B) should
face to inside.
4. After installing the tie rod (C), install the lock nut (B)
and split pin (A).
Tightening Torque :
69~118 Nm (7~12 kgfm, 51~87 lb-ft)
KMTPA303A
KMTPA305A
3. After installing the lock pin (C), install the lock pin
washer (B) and nut (A).
Tightening Torque :
28~38 Nm (2.9~3.9 kgfm, 21~28 lb-ft)
5. After installing the drag link (C), install the lock nut
(B) and split pin (A).
Tightening Torque :
196~294 Nm (20~30 kgfm, 145~217 lb-ft)
KMTPA302A
KMTPA304A
6. After install the brake caliper (B), install the caliper

tightening bolt (A).
Tightening Torque : 98~127 Nm (10~13 kgfm, 72~94
lb-ft)
SUDPAA002L
7. After installing the dust cover (B) to the knuckle (C),

install the tightening bolt (A) of the dust cover.
Tightening Torque : 98~137 Nm (10~14 kgfm, 72~101
lb-ft)
8. After installing the brake assembly (B) to the knuckle
(C), install the tightening bolt (A) of the brake
assembly.
Tightening Torque : 125~139 Nm (12.7~14.2 kgfm,
92~103 lb-ft)
9. Install the wheel hub. (Refer to the Wheel Hub
Assembly)
Wheel Alignment
Description
When wheel alignment and steering angle are measured,
check that the vehicle has no load or every parts of the
front axle are properly assembled.
4. Moving the vehicle to forward so that the marking

point moves backward. Setting the marking point to
the height of the toe-in gauge (i.e. turn 180), at the
rear side, measure the distance (B) between the two
wheels.
CAUTION
Before the adjustment, check again followings.
1. The front wheel is loosened.
2. The knuckle is loosened.
3. The linkage between the knuckle flange and
knuckle arm is loosened.
4. The bolts, the screws or the nuts are loosened.
5. The leaf spring is damaged or weakened.
6. The tire air pressure is too high or low.
7. The adjusted backlash of the steering gear is
proper.
Inspection
Toe-in
1. Set the front wheel along with the straight direction.
2. Make a mark at the front end of the front wheel. (The
marking point is the middle position of the width and
height of the wheel)
3. Setting the needle height of the toe-in gauge to the
marking point of the left and right tire, measure the
toe-in value. Measure the distance (A) between the
two wheels.
KMTAX5020A
5. The difference between the measured value of rear

side (B) and the measured value of front side (A) is
the toe-in value.
Specified Value (B-A): 1~3mm
KHHA850A
KMTAX5019A
6. If the measured toe-in value excesses the specified

value, adjust it by loosening the clamp bolts (B) of the
left and right tie rods (A) and turning the tie rod (A)
with a pipe wrench (C).
3. Wipe out the grease at the end of the spindle. Install

the self centering plunger of the camber, the caster
and the king pin gauge (A) to the wheel hub by
setting them to the center hole of the spindle.
Tightening Torque of the Clamp Bolt (B):

20~29 Nm (2~3 kgfm, 14~22 lb-ft)
EMTPA5026A
Camber
KMTPA362A

2. Remove the wheel hub cap (A).
4. Set the gauge (A) in horizontal plane. To do that, set

the bubble (in longitudinal direction) of the level
gauge to the zero point.
5. Measure the camber value(B) of the gauge (A). The
center line of the bubble is the camber value.
Specified Value : 130
KMTPA361A
KMTPA363A
6. By the same method, measure the camber value of

the opposite wheel.
Kingpin inclination angle and Caster

1. To maintain the vehicle in horizontal position, place a
plate (B) having the same height with the turn table
(A) under the rear tire (C).
4. Turn the tire to be measured to the outward until the

scale of the turn table is positioned 20 (A).
KMTPA363A
5. Remove the wheel hub cap (A).

KMTPA371A
2. Positioning the two front tires of the vehicle to the

center of the turn table, pull (set up) the parking
brake.
CAUTION
If it is hard to move the vehicle, lift up the
vehicle with a jack and place the turn table and
the plate under the front and rear tire.
3. Set the scales of the both turn table to zero point.
KMTPA373A
6. Wipe out the grease at the end of the spindle. Install

the self centering plunger of the camber, the caster
and the king pin gauge (A) to the wheel hub by
setting them to the center hole of the spindle.
7. Set the gauge (A) in horizontal plane. To do that, set
8. By turning the zero setting screws of the caster (A)

under the gauge and the kingpin tilting angle, set the
bubble to 0.
CAUTION
For left side wheel, use the left scale as the
kingpin tilting angle scale. For right side wheel,
use the right scale as the kingpin tilting angle
scale.
Steering Angle
Before inspecting the steering angle, complete the
inspection of the wheel alignment.
1. To maintain the vehicle in horizontal position, place a
plate (B) having the same height with the turn table
(A) under the rear tire (C).
9. Turn the wheel 20 again so as to set the scale of the

turn table to 0. Then the center line of the bubble
indicates the kingpin tilting angle value. Measure the
center line value of the bubble.
Specified Value : 810
10.By turning the tire to inward, set the scale of the turn
table to 20.
11.Set the gauge (A) in horizontal plane. To do that, set
12.From the caster scale, read the each pointing scale
of the casters.
Specified Value: 130
13.By the same method, measure the caster and the
kingpin tilting angle values of the opposite wheel.
KMTPA371A
2. Positioning the two front tires of the vehicle to the

center of the turn table, pull (set up) the parking
brake.
CAUTION
If it is hard to move the vehicle, lift up the
vehicle with a jack and place the turn table and
the plate under the front and rear tire.
3. Set the scales of the both turn table to 0.
4. Turn the tire to inward. Measure the scale of the turn
table.
Specified Value() : 40.8~42.8
5. Turn the tire to outward. Measure the scale of the
turn table.
Specified Value() : 30.8~32.8
6. If the measured value excesses the specified value,

tighten or loosen the knuckle stopper bolt (A) at both
sides (LH/RH) to adjust the steering angle.
Side Slip
Before checking the side slip, complete the inspection of
the wheel alignment.
2. Maintaining the position of the front wheel to the
straight direction, drive the vehicle on the slip tester
slowly.
CAUTION
With maintaining the position of the front wheel
to the straight direction, pass through the side
slip tester thoroughly. Do not turn the wheel or
do not fall off from the tester.
3. The value indicated on the tester is the side slip. If
the side slip excesses the specified value, the wheel
alignment should be adjusted.
Specified Value: 3mm/(when going straight per 1m)
KMTPA382A
7. After adjusting the steering angle, tighten the nut (A)

of the stopper bolt with specified torque.
Tightening Torque :
19.6~29.4 Nm (2~3 Kgfm, 14.4~21.6 lb-ft)
KMTPA383A
Rear Axle
Wheel Hub
Components
SUDPAA003L
1. Brake Pipe
2. Bolt
3. Rear Axle Shaft
4. Outer Oil Seal
5. Rear Brake Assembly
6. Bolt
7. Lock Plate
8. Lock Nut
9. Wheel Hub Outer Bearing Inner Race
10. Wheel Hub and Drum Assembly
11. Inner Oil Seal
12. Wheel Hub Outer Bearing Outer Race
13. Wheel Hub Inner Bearing Outer Race
14. Nut
CAUTION
Be careful that the brake lining and the brake
drum inner surface are not contaminated by the
oil or grease.
15. Hub Bolt

16. Rear Wheel Hub
17. Rear Brake Drum
18. Wheel Hub Inner Bearing Inner Race
19. Nut
Removal
sides of the front wheel.
3. After taking off the wheel nut (A), remove the wheel
CAUTION
KMTPA401A
2. Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand
(B).
KMTPA403A
4. After taking off the hub bolt (A), remove the axle shaft
(B).
NOTICE
When it is hard to remove the axle shaft (B), insert
hub bolts (A) into the removing screw holes (C)
evenly.
KMTPA402A
KMTPA404A
5. Remove the oil seal (A).
7. Using the special tool (09527-47000), remove the

lock nut (A).
KMTPA405A
6. Loosening the tightening bolt (A) for the lock nut,

remove the lock washer (B).
KMTPA407A
8. Remove the rear wheel hub (B) with the outer

bearing (C) from the axle housing (A).
CAUTION
Be careful that the outer hub bearing (C) do not
drop down to the ground.
KMTPA406A
KMTPA408A
Disassembly
1. Tapping evenly the three notch parts on the hub inner
surface with a brass bar, removing the oil seal (A),
the inner bearing (B) and the inner bearing race (C).
2. Tapping evenly the three notch parts on the other

side hub inner surface with a brass bar, removing the
outer bearing race (A).
KMTPA410A
KMTPA409A
NOTICE
When using a brass bar, do not tap except the notch
parts (A) located inside of the hub.
3. After taking off the hub nut (A), remove the drum (C)
from the wheel hub (B).
KMTPA411A
KMTPA420A
Inspection
Reassembly
1. Check that the rotation state is proper after installing

the bearing(A) to the bearing race(B). If it has been
adhered, worn or defective in rotation, replace the
bearing(A) and the bearing race (B) in a set.
1. Installing the drum (C) to the wheel hub (B), tighten

the hub nut (A).
CAUTION
After tightening the hub nut (A), at least 4
portions of the groove parts of the stud should
be calked.
Tightening Torque : 304~382 Nm (31~39 Kgfm,
224~282 lb-ft)
KMTPA409A
2. If the hub bolt is worn or corroded, remove the hub

bolt from the wheel hub and replace it.
KMTPA411A
2. By tapping evenly, install the inner bearing race (B)

and the outer bearing race (C) at the wheel hub (A).
KMTPA412A
3. Install the inner bearing (B) and the oil seal (C) at the
wheel hub (A).
CAUTION
race.
Replace the oil seal (C) with new ones after
removal.
KMTPA408A

a. With rotating the hub assembly (B), tighten the
lock nut (A) fully with the force of 98~127 Nm
(10~13 kgfm, 72~94 lb-ft). After that, loosen the
nut fully.
KMTPA413A

b. Again with rotating the hub assembly (B), tighten

the lock nut (A) with the force of 29~39 Nm (3~4
kgfm, 22~29 lb-ft).
Recommended Grease:
MS511-33
5. Install the rear wheel hub (B) and the outer bearing
(C) to the axle housing (A).
CAUTION
race.
KMTPA211A
7. Setting the lock washer (A) to the spindle groove (B)

of the housing, tighten the lock nut tightening bolt (C).
Tightening Torque : 7~11 Nm (0.7~1.1 Kgf.m, 5~8 lb-ft)
KMTPA415A

the starting torque by multiplying the tangential force
to the radius.
9. Install the oil seal (A).

CAUTION
Use a new oil seal (A) always.
KMTPA405A
10.After installing the axle shaft (B), tighten the hub bolt
(A) with specified torque.
Tightening Torque : 98~117 Nm (10~12 Kgf.m, 72~87
lb-ft)
Starting Torque : 2~4 Nm (0.2~0.4 Kgf.m, 1~3 lb-ft)
KMTPA416A
KMTPA212A
11.After installing the wheel and tire (B) to the hub (C),
KMTPA403A
12.After removing the garage jack (A) supporting the

axle and the safety stand (B) supporting the frame,
tighten the wheel nut with the specified torque.
Tightening Torque : 539~588 Nm (55~60 Kgf.m,
398~434 lb-ft)
KMTPA402A
KMTPA401A
Axle Housing
Components
SUDPAA010L
1. Drain Plug
2. Oiling Plug
3. Nut
4. Bolt
5. Reduction and Differential Assembly
6. Nut
7. Rear Axle Housing
Disassembly
3. After taking off the wheel nut (A), remove the wheel
CAUTION
KMTPA401A
2. Loosen the wheel nut. Lift up the axle with a garage

jack (A) and support the frame with a safety stand
(B).
KMTPA403A
4. As the same method with the 2~3 steps, remove the

opposite side wheel and tire.
5. Support the both hub with a jack (A).
KMTPA402A
KMTPA501A

propeller shaft.
8. After taking off the tightening nut(A) of the shock

absorber, remove the shock absorber (B).
KMTPA503A
KMTPA113A
9. After taking off the tightening nut (A) of the U-bolt,

remove the U-bolt (B).
7. After removing the brake line (A), remove the brake

hose clip (B).
NOTICE
If the brake line is rubber hose, remove it after
biting it with vise pliers.
If the brake line is steel pipe, remove the line
with pressing the brake pedal.
KMTPA504A
KMTPA502A
10.After getting down the jack (A) supporting the both

hub, remove the axle housing (B).
2. Setting the center bolt (A) of the leaf spring to the

center hole (B) of the axle housing, lift up the axle
housing (C) completely.
KMTPA505A
KMTPA510A
Reassembly
1. After positioning the axle housing (B) at the rear side
of the vehicle, lift up the jack (A) supporting the both
hubs slowly.
3. After installing the U-bolt (B), tighten the U-bolt

tightening nut (A) with the specified torque.
166~188 lb-ft)
KMTPA505A
KMTPA504A
4. After installing the shock absorber (A), tighten the

shock absorber tightening bolt (A) with the specified
torque.
Tightening Torque : 26~33 Nm (2.7~3.4 kgfm, 20~25
lb-ft)
KMTPA502A
6. Setting the align marks (C) of the rear axle

companion flange (A) to the flange yoke (B) of the
rear propeller shaft, install the tightening bolt (D) of
the propeller shaft.
KMTPA503A
5. After installing the brake hose clip (B), install the

brake line (A).
Tightening Torque : 98~107.8 Nm (10~11 kgfm,

72.3~79.5 lb-ft)
NOTICE
If the brake line is rubber hose, remove the vise
pliers after installing the line.
If the brake line is steel pipe, release the brake
pedal after installing the line.
Tightening Torque : 25~29 Nm (2.5~3.0 kgfm, 18~22

lb-ft)
KMTPA113A
7. Remove the jack (A) supporting the both hub.
9. After removing the garage jack (A) supporting the

axle and the safety stand (B) supporting the frame,
tighten the wheel nut with the specified torque.
398~434 lb-ft)
KMTPA501A
8. Install the wheel and tire (B) to the hub (C). Tighten
the wheel nut (A).
KMTPA402A
KMTPA403A
KMTPA401A
11.Bleed the brake system. (Refer to the "Air Bleeding of

BR Group")
Rear Axle(F302,F320)
ADJUSTMENT
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:
1) On completion of running at beginning of vehicle
(2500 Km of travel)
2) Every 24000 Km of travel
3. 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.
NOTICE
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. 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.
2. Connection of ABS (If installed)
1) Range of electric resistance of sensor: 1550-1700
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.
SUDPAA011L
1. HARD PIPE ASSY-LH

2. 3-WAY VALVE TRANSITION BRACKET ASSEMBLY (for ABS)
3. HOSE (2 for ABS)
4. HARD PIPE ASSY-RH
5. BOLT
BOLT (transition bracket assembly, for ABS)
6. BOLT
CLIP
7. WIRE HARNESS ASSEMBLY (left)

8. WIRE HARNESS ASSEMBLY(right)
9. STRAP
10. BREATHER PLUG
11. Oil filler plug
12. Oil drain plug
NOTICE
The brake tubes 1 and 4 should be mounted as
per the steps as given in Fig. which facilitates
assembling and sealing.
SUDPA7038L
On completion of assembling of the complete

axle, oil should be applied as specified.
Test specification for rear axle assembly
INSPECTION
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.
1. Cleaning
WARNING
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. 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.
2. 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.
3. A defect found in the test may be reconditioned.
However, reacceptance is required after the
reconditioning.
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.
2. 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.
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.
3. Reconditioning and Replacement
NOTICE
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.
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.
SPECIFICATION
Model (F320)
Description
Specification
Vehicle
HD72
Model
F320
Engine corresponded
Gear ratio
Quantity(L)
Oil spec
D4DA, D4DB, D4DD
D4AL, D4DC
5.428
6.666
5.3~5.7
Temperate or frigid zone
GL-5 SAE 80W/90
Torrid zone
GL-5 SAE 85W/140
Grease
NLGI No.2
Brake size(mm)
320 x 85
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
Vehicle
Model
HD65
F302
Engine corresponded
D4AL, D4DC, D4BD
Gear ratio
6.166
Quantity(L)
Oil spec
Specification
4.3~4.7
Temperate or frigid zone
GL-5 SAE 80W/90
Torrid zone
GL-5 SAE 85W/140
TIGHTENING TORQUE
Specification (F320)
Specification (F302)
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
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
330~390
SERVICE STANDARD
Item
Backlash of pinion and ring gear
Variation of backlashes for the same pair of gears
Oil capacity of rear axle hypoid gear
Specification
0.15~0.3 mm
Not greater than 0.08 mm
F320 : 5.5L, F302 : 4.5L
Wheel Hub
COMPONENTS
1. Part list and exploded view of wheel end part.
SUDPAA012L
1. REAR AXLE ASSY

2. SPACING RING
3. BRAKE ASSY-LH
4. BRAKE ASSY-RH
5. NUT
6. SPRING WASHER
7. BOLT
8. INNER OIL SEAL ASSY-HUB
9. SPACER
10. CUP-BEARING
11. CONE & ROLLER ASSY
12. DRUM
13. GEAR RING-ABS
14. NUT (12 for F320 series: 10 for F302 series)
15. HUB-RR WHEEL
NOTICE
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.
16. BOLT-HUB,LH (6 for F320 series: 5 for F302 series)

17. BOLT-HUB,RH (6 for F320 series: 5 for F302 series)
18. CUP-BEARING
19. CONE & ROLLER ASSY
20. NUT
NUT
21. LOCK WASHER
22. CROSS GROOVE BOLT
23. OUTER OIL SEAL ASSY-HUB
24. AXLE SHAFT-RH
25. AXLE SHAFT-LH
26. BOLT
2. Equipment and adjustment of wheel end part
REPLACEMENT
1. Dismounting of wheel end part
1) 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.
NOTICE
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.
SUDPA7035L
1) 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).
NOTICE
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
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.
NOTICE
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.
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.
NOTICE
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.
NOTICE
1. A proper pressing tool should be used for
mounting of the oil seal. An inappropriate tool
may cause damaged oil seal.
2. The oil seal may be prone to damage and

should be placed in the package before
assembling.
3. 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.
2. 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.

COMPONENTS
SUDPAA013L
1. Nut-flange
2. Washer
3. O ring
4. Flange assy
5. Oil seal assypinion
6. Outer bearing-pinion
7. Bolt
8. Bearing cage
9. Adjusting shim
10. Inner bearing-pinion

11. Split pin
12. Pinion
13. Pilot bearing
14. Adjusting shim
15. Bolt
16. Bolt
17. Diff. carrier
18. Adjusting ring
19. Bearing
20. Differential case (right)
21. Differential side gear shim
22. Bolt
23. Spring washer
24. Lock piece
25. Bolt
26. Cover
27. Differential side gear
28. Differential pinion gear shim

29. Differential pinion gear
30. Cross shaft
31. Ring gear
32. Differential case (left)
33. Bolt
34. Bolt
REMOVAL
CAUTION
When axle shaft is dismantled, please distinguish
left from right axle shaft, thus mistake will not be
made in re-installation.
The carrier is dismantled according to the following steps
1. Release and draw out left/right axle shaft.
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").
SUDPA7002L
2. Support the carrier with cart, dismantle 12 bolts

linking carrier and rear axle, dismantle the carrier
assembly from axle housing.
WARNING
1. Don't use hammer to knock on the edge of
axle shaft flange, don't prize axle shaft or
screw by such tools as flat spade!
2. Don't lie under carrier while dismantling or
installing tightening bolts of carrier. Cart
shall be used to transport carrier.
INSTALLATION
1. ASSEMBLY OF DIFFERENTIAL CARRIER
CAUTION
1. Before carrier is installed, one shall assure
the interior of axle housing has been checked
and cleared utterly
2. On the engagement face between axle
housing and carrier, heavy load sealing glue
will be applied.
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).
2. Mounting of pinion assembly
1) 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.
NOTICE
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.)
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.
DISASSEMBLY
CAUTION
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 steps for replacing pinion and ring gear
SUDPA7026L
3. Mounting of differential assembly

NOTICE
Lubricate the differential bearing.
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.
1) Mount the differential assembly onto the carrier.
SUDPA7004L
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.
NOTICE
It may be difficult to screw on the adjusting ring if
the ring and the relevant threads are not
lubricated.
2. 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.
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.
Dismantle pinion assembly
SUDPA7007L
CAUTION
When dismantling flange assembly, don't lay pinion
on hard surface.
2. Take down the cup-bearing-inner.
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.
SUDPA7009L
SUDPA7008L
3. Take down the cone & roller assy-outer.
SUDPA7010L
4. Dismantle guide bearing of pinion
SUDPA7011L
SUDPA7012L
NOTICE
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.
INSPECTION
DETECTION AND MAINTENANCE ON DIFFERENTIAL ASSEMBLY
SUDPA7013L
NOTICE
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.
1. Dismantle the linking bolt tightening ring gear and

differential case, if ring gear doesnt 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.
4. Dismantle differential pinion gear and cross shaft

assembly, then dismantle shim and differential pinion
gear from cross shaft.
SUDPA7014L-1
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).
SUDPA7014L-4
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.
SUDPA7014L-2
3. Take down side gear shim and side gear.
SUDPA7015L
SUDPA7014L-3
REASSEMBLY
ASSEMBLY ON DIFFERENTIAL ASSEMBLY
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 )
3. 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.
1. Assemble the cone & roller assy.
SUDPA7016L-3
4. Assemble side gear and side gear shim.
SUDPA7016L-1
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.
NOTICE
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. Assemble side gear shim and side gear into
differential case(left).
SUDPA7016L-5
SUDPA7016L-2
6. Assemble ring gear, assemble bolt linking ring gear

and differential case, tighten bolt to correct torque.
SUDPA7016L-6
ASSEMBLE AND ADJUST PINION ASSEMBLY
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).
2. Adjustment on the pre-tightened force of bearing

inside pinion.
1) 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.
1. Assembling components of pinion assembly

1) 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
SUDPA7020L
SUDPA7018L
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.
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.
2) Pressing pilot bearing into pinion.
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.
CAUTION
After having confirmed value of torque, start
to rotate bearing cage.
SUDPA7019L
4) 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.
3. Final test on pinion bearing for pretightening force

1) Assemble the pinion, the bearing and the bearing
cage
SUDPA7022L
SUDPA7021L
NOTICE
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.
2) 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.
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.
NOTICE
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.
4. Mounting of oil seal and flange
5. Requirement and method for reassembly of flange

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.
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.
SUDPA7025L
SUDPA7024L
NOTICE
At the point A in the size of the pressing sleeve
should be ensured.
2) 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.)
NOTICE
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.
NOTICE
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.
NOTICE
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.
SUDPA7029L
ADJUSTMENT
1. 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.
NOTICE
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.
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.
SUDPA7030L
SUDPA7031L
SUDPA7028L
NOTICE
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.
2. 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
SUDPA7033L
NOTICE
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.
3. Adjustment of contact pattern of pinion and ring gear
Adjustment of contact pattern of pinion and ring gear

Contact pattern of ring gear
Adjusting methed
Convex side
Concave side
Move the ring gear towards
the pinion.
If the backlash is too small
at the moment, move the pinion away.
Move the ring gear away from the pinion.

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

ring gear.
If the backlash is too small
at the moment, move the ring gear away.
Move the pinion away from the ring gear.

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

Components
SUDPAA014L
1. Self Locking Nut

2. O-Ring
3. Companion Flange
4. Dust Cover
5. Oil Seal
6. Pinion Bearing
7. Pinion Bearing Collar
8. Pinion Inner Bearing
9. Bearing Retainer
10. Pinion Driver
11. Pinion Pilot Bearing (ONLY D033H)
12. Lock Ring (ONLY D033H)
13. A/B Shim

14. Bolt
15. Spring Washer
16. Pin
17. Bolt
18. Spring Washer
19. Differential Collar
20. Adjust Screw
21. Side Bearing
22. Bolt
23. Differential Case, LH
24. Drive Gear
CAUTION
The bearing cap and the differential carrier
should be replaced as a set.
25. Differential Case RH

26. Differential Case Bolt
27. Differential Gear
28. Differential Gear Washer
29. Differential Pinion Washer
30. Differential Pinion
31. Differential Spider
32. Side Bearing Cap
33. Lock Plate
34. Bolt
35. Spring Washer
36. Bearing Cap Bolt
Removal
3. Remove the axle shaft at the opposite side also.
1. After removing the drain plug(A), drain out the gear

oil.

propeller shaft.
KMTPA610A
2. After taking off the hub bolt (A), remove the axle shaft
(B).
NOTICE
When it is hard to remove the axle shaft (B), insert
hub bolts (A) into the removing screw holes evenly.
KMTPA113A
5. Disassemble the contacting surface between the rear

axle companion flange (A) and the flange yoke (B) of
the rear propeller shaft.
CAUTION
As this part is very heavy, be careful the
precautions. Before the working, be sure that it
is supported by jack.
KMTPA611A
KMTPA613A
6. After taking off the differential carrier tightening bolt

and nut (A), remove the differential carrier assembly
(B) from the axle housing (C).
2. Setting the aligning mark (C) of the rear axle

companion flange (A) to that of the flange yoke (B) of
the rear propeller shaft, tighten the bolt (D) of the
propeller shaft.
Tightening Torque :
98~107.8 Nm (10~11 kgfm, 72.3~79.5 lb-ft)
KMTPA614A
Installation
1. After installing the differential carrier assembly (B) to
the axle housing (C), tighten the differential carrier
tightening bolt (A) with the specified torque.
Tightening Torque :
49~58.8 Nm (5~6 kgfm, 36.1~43.3 lb-ft)
KMTPA113A
3. After installing the axle shaft (B), tighten the hub bolt
(A) with the specified torque.
Tightening Torque :
98~118 Nm (10~12 kgfm, 72~87 lb-ft)
KMTPA614A
KMTPA611A
4. Install the rear axle shaft of the opposite side.
2. Remove the differential carrier bearing cap bolt (A).
5. Fill in the recommended oil.

Recommended Oil: API GL-5, SAE 80W/90
Oil Amount: 4.50.25
KMTPA702A
3. After removing the bearing cap(A), remove the side

bearing nut (B).
KMTPA661A
Disassembly
1. Fix the differential carrier (A) at the vise or the
working base.
KMTPA703A
4. Remove the differential carrier assembly (A) and the

side bearing race (B) from the differential carrier
collar (C).
KMTPA701A
KMTPA704A
5. After removing the side bearing (A), remove the

differential case bolts (B).
KMTPA705A
6. After removing the differential case, remove the

differential pinion, the differential pinion washer, the
differential gear, the differential gear washer and the
differential spider, sequentially.
9. Remove the pinion drive (A), the inner bearing (B),

the space (C) and the shim (D).
KMTPA709A
10.Remove the oil seal (A) and the outer bearing (B).
7. After taking off the tightening bolt of the drive gear,

disassemble the differential case and the driver gear.
8. Remove the self locking nut (A) and the companion
flange (B).
KMTPA710A
11.Remove the bearing race (A), the oil stopper (B) and
the outer bearing race (C) from the differential collar.
KMTPA708A
KMTPA711A
KMTPA709A
Reassembly
1. Install the outer bearing race (C), the oil stopper (B)
and the bearing race (A) into the differential collar.
4. Install the companion flange and the self locking nut

(A).
Tightening Torque :
D033H 373~471 Nm (38~48 kgfm, 275~347 lb-ft)
R130HS 196.1~343.2 Nm (20~35 kgfm,
144.6~253.1 lb-ft)
KMTPA711A
2. Install the outer bearing (B) and a new oil seal (A).
KMTPA708A
5. After assembling the differential case and the drive

gear, install the drive gear tightening bolt.
166~195 lb-ft)
6. After installing the differential pinion, the differential
pinion washer, the differential gear, the differential
gear washer and the differential spider, install the
differential case.
7. After installing the differential case bolt (B), install the
side bearing.
KMTPA710A
3. Install the shim (D), the space (C), the inner bearing
(B) and the pinion drive (A).
KMTPA705A
8. Install the differential carrier assembly (A) and the

side bearing race (B) at the differential carrier collar
(C).
KMTPA704A
9. After installing the side bearing nuts (B), install the

bearing cap (A).
Tightening Torque : 69~78 Nm (7~8 kgfm, 51~58 lb-ft)
KMTPA703A

Hyundai HD78 Propeller Shaft and Axle (Мост и Редуктор)

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Hyundai HD78 Propeller Shaft and Axle (Мост и Редуктор)

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Propeller Shaft and

Differential Carrier Assembly

Outer Diameter Thickness

Spider Outer Diameter

Bearing Cap Outer Diameter

Inner Diameter Outer Diameter

Needle roller Bearing

King Pin Offset (mm)

King Pin Span (mm)

King Pin Tilting Angle

D2H, D3H, D033H, R130HS

Straight Bevel Gear

API GL-5, SAE 80W/90

Propeller Shaft Run-out

Clearance between Spider and Needle Bearing

Clearance of Snap Ring to axis

Unbalance of Propeller Shaft

Remedy and Remark

Replace with spider kit

Remedy and Remark

King Pin Outer Diameter

Bushing Inner Diameter

Replace the bushing

Adjust with Shim

Clearance between King pin

Front Wheel Hub Starting Torque (kgfcm)

0.98~3.45 Nm (10~35kgfcm, 0.73~2.55 Ib-ft)

Bending of shaft center

Run-out of the back surface the final drive gear

Starting torque of Rear wheel hub(kgf.m)

Remedy and Remark

Adjust (do not install the outer

Lock nut for tightening the companion

Center bearing bolt tightening

Tightening Nut for King pin Lock pin

Tightening Nut for Shock Absorber

Tightening Bolt for Brake Backing Plate

Tightening Nut for Hub bolt

Tightening Nut for Knuckle Arm

Tightening the wheel hub lock nut

1st tightening torque

Approximately 45 <1/8 turns>

Tightening bolt for bearing cap

Bolt (for install the side bearing lock plate)

Tightening Nut for differential carrier assembly

Tightening Bolt for rear brake assembly

Tighten the wheel bearing 1st tightening

Tightening Bolt for rear axle shaft

Replace the propeller shaft.

The flange linking bolt is loosened.

Tighten with specified torque.

The ball bearing is worn out or adhered.

Replace the ball bearing.

The transmission is too fast.

Move the shift bar of the transmission to proper position.

The clearance of the slip joint spline is too large.

Replace the yoke sleeve or propeller shaft.

The flange linking blot is loosened.

Tighten with specified torque.

The tightening bolt for center bearing is loosened.

Tighten with specified torque.

The center bearing is weakened or deformed.

Replace the rubber

The universal joint needle roller bearing is worn.