TRANSFER UNITS

Specifications .......................................................................................... 4 – 1
Structure and Functions ....................................................................... 4 – 2
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 4 – 4
Disassembly ............................................................................................. 4 – 4
Inspection after Disassembly .................................................................... 4 – 5
4
Reassembly .............................................................................................. 4 – 6
Service Data ............................................................................................ 4 – 8
 TRANSFER UNITS

Specifications

Truck Model
Item 1 ton class 2 ton class

Gear type Constant-mesh type, 3 stages (helical gears)

Transfer
58 x 83 x 45 =20.151
Reducing gear ratio
24 16 28

4-1
TRANSFER UNITS

Structure and Functions (Part 1)

Front of vehicle
7
7

A 8 8 A

6 6

1 3

4
5
2

206785

1 Transfer (left) 6 Wheel hub

2 Traction motor (left) 7 Front tire
3 Transfer (right) 8 Bracket
4 Traction motor (right) 9 Tension rod
5 Frame Section A: Mast support mounting section

Since two traction motors are installed in a limited Sections A support masts.
space, the traction motors are offset in position.
Tension rod 9 connects brackets 8, and includes a
turnbuckle to serve as a thrust rod for the left and right
transfer units.

4-2
 TRANSFER UNITS

Structure and Functions (Part 2)

18
7 Left side
9 10 14 5
6

17
18
11

Front of vehicle
6 12 13
Right side
4
17
16
15

3 1

15

2 (View from left side)

Bolts marked with × : Bolts for mounting transfer units to frame 211046

1 Traction motor 8 Main case 15 Ball bearing

2 Input gear 9 Nut 16 Generator
3 Second gear 10 Plate (DC motor models only)
4 Third gear 11 Spacer 17 Oil level plug
5 Output shaft 12 Retainer 18 Air breather
6 Wheel hub 13 Taper roller bearing
7 Cover 14 Oil seal

The left and right transfer units are identical, and are The generator detects rotating speed.
mounted on the frame with bolts marked with an × in Helical gears are used for reduced operating noise.
the diagram.
The output shaft is provided with two taper roller
The left and right transfer units are installed to the bearings to withstand heavy loads.
traction motors. The motor shafts are jointed to the
involute splines of the input gears.
Transfer reducing
Driving force is transmitted via the input gear, second 20.151
gear ratio
gear, third gear, then to the output shaft that rotates the
wheel hub.

4-3
TRANSFER UNITS

Procedures and Suggestions for Disassembly and Reassembly

Preparation
1. Remove the power train consisting of the transfer, 2. Drain oil from the transfer.
traction motor and caliper. (Refer to Removal and 3. Remove the traction motor and caliper.
Installation of Power Train.)

Disassembly

8
12
9 19
7

6
5
4
3 10

11
18

16
17 14
15 13
18
2 16 14

1
211047

Sequence
1 Bolt 10 Output shaft, O-ring
Remove parts 2 to 12 as sub-assembly. 11 Taper roller bearing
2 Cover 12 Oil seal
3 Cap 13 Input gear
4 Nut 14 Ball bearing
5 Plate 15 Second gear
6 Spacer, O-ring 16 Ball bearing
7 Wheel hub, Hub bolt 17 Third gear
8 Taper roller bearing 18 Ball bearing
9 Retainer 19 Main case, Dowel pin

4-4
 TRANSFER UNITS

Suggestions for Disassembly

1. Removing nut 4
Nut 4 is secured to output shaft 10 by punching.
Use a chisel to scrape punched section carefully. Do not
scratch output shaft 10.
Nut 4 is not reusable.

206789

2. Cover 2
Outer laces of taper bearings 8 and 11 that are press-fit into
cover 2 do not have to be disassembled if inspection finds
no abnormality.
Remove oil seal 12, and use a new seal.

Inspection after Disassembly

1. Inspect the gear teeth and splines for wear and damage.
2. Inspect the bearings for wear, damage, rotating
resistance and noise.
3. Inspect main case 19 and cover 2 for cracking and
damage.
4. Inspect the oil seal contact surface of retainer 9 for
scratches and damage.

4-5
TRANSFER UNITS

Reassembly

1 12
6 4 5

11

10

9 14

7 3 2

14
13

15
16

16

18

17
18

19

211048

Sequence
Assemble parts 1 to 4 prior to final assembly. 8 Spacer, O-ring
1 Cover 9 Plate
2 Taper roller bearing (outer) 10 Nut
3 Taper roller bearing (outer) 11 Cap
4 Oil seal 12 Main case
5 Output shaft, Inner lace of taper roller bearing 13 Third gear
2, O-rings 14 Ball bearing
Assemble parts 6 and 7, and inner lace of taper roller 15 Second gear
bearing 3 prior to final assembly. 16 Ball bearing
6 Wheel hub, Hub bolt 17 Input gear
7 Retainer 18 Ball bearing
Install sub-assemblies 5 and 6 in cover 1. 19 Bolt

4-6
 TRANSFER UNITS

Suggestions for Reassembly

1. Inspect the mounting surfaces of cover 1 and main case
Unit: mm
12 for dents and burrs, and clean the surfaces.
2. To install oil seal 4, use a jig. Tap the jig to fit the oil 3- φ16.5
seal evenly. 2- φ18

Apply a thin coat of liquid gasket (Three Bond #1104) 80

109
on the oil seal mounting surface of cover 1.

50
68

54
3. Tighten nut 10, and check the preload of taper roller

.2
bearings 2 and 3. 10
When tightening the nut, insert vinyl tubes on three
symmetrical locations relative to the hub bolt and use a
hub holding tool. 207207
Hub holding tool: To be fabricated at service location

NOTE

Cut a vinyl tube with an inside diameter of 14 mm

(0.55 in.) into pieces of 25 mm (1 in.) in length, and
use these vinyl tube pieces to protect the screw sections
when using the spring scale for measurement.

Preload

Tangential force 59 to 88 N
206791
on hub bolt (6 to 9 kgf)
[13.3 to 19.8 lbf]

4. After checking preload, stake one side of nut 10 with a

dull punch to secure the nut in place.
Make sure the groove is flattened completely and the
Unit: mm (in.)
flattened area measures more than 4 mm (0.16 in.) in
diameter.

5. When installing cover 1 sub-assembly on main case

12, apply a thin coat of liquid gasket (Three Bond
#1104) on the mounting surfaces.
φ4
Tighten bolt 19 to the specified torque. (0.16)

108 ± 10 N·m
Bolt tightening torque (11.0 ± 1.0 kgf·m)
206792
[79.7 ± 7.4 lbf·ft]

4-7
TRANSFER UNITS

Service Data A: Standard value

Unit: mm (in.)
Truck Model
1 ton class 2 ton class
Item
Input gear and second gear 1 A 0.11 to 0.24 (0.0043 to 0.0094)
Gear backlash Second gear and third gear 2 A 0.11 to 0.24 (0.0043 to 0.0094)
Third gear and output shaft 3 A 0.12 to 0.30 (0.0047 to 0.0118)
Preload of output shaft and taper roller bearing 4
Tangential force on hub bolt A 59 to 88 (6 to 9) [13.3 to 19.8]
N (kgf) [lbf]
Tightening torque of cover mounting bolt 5
N·m (kgf·m) [lbf·ft] A 108 ± 10 (11.0 ± 1.0) [79.7 ± 7.4]

Transfer

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4-8