JLG 3507 Supplemental Repair Manual
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JLG 3507 Supplemental Repair Manual

Drive axle
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Download this manual See also: Service Manual, Operator's Manual
Drive Axle
Supplemental Repair Manual
Models
3507, 3508, 3509,
3512, 3513, 4007,
4008, 4009, 4012,
4013, 4017, G6-42A,
642, TF6-42, TL642,
& TL642C
JLG - 31200162
Component Manufacturer
ASM-0025E
Revised
May 6, 2015
An Oshkosh Corporation Company

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  • Page 1 Drive Axle Supplemental Repair Manual Models 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013, 4017, G6-42A, 642, TF6-42, TL642, & TL642C JLG - 31200162 Component Manufacturer ASM-0025E Revised May 6, 2015 An Oshkosh Corporation Company...
  • Page 2 DISCLAIMER: Information provided within is supplied directly from the component manufacturer. The information has not been altered in any way and is the sole property of the component manufacturer. Due to continuous improvements, the component manufacturer reserves the right to make changes without prior notification.
  • Page 3 Service Manual Axle 212 ASM-0025E October 2013...

  • Page 5: Table Of Contents

    CONTENTS INTRODUCTION ..........................7 SPECIFICATIONS ..........................9 DEFINITION OF VIEWPOINTS ......................... 9 DATA PLATE ............................9 CONVERSION TABLES ..........................10 TORQUE SPECIFICATIONS ......................... 11 COARSE PITCH ............................11 FINE PITCH .............................. 11 WHEEL NUT TIGHTENING TORQUES ....................12 MAINTENANCE ............................13 MAINTENANCE POINTS .........................
  • Page 6 DIFFERENTIAL UNIT ........................61 EXPLODED VIEW ............................61 DISASSEMBLY ............................. 62 ASSEMBLY ..............................64 SPECIAL TOOLS ............................66 T1 ................................66 T2 ................................66 BEVEL PINION ........................... 67 EXPLODED VIEW ............................67 DISASSEMBLY ............................. 68 ASSEMBLY ..............................71 SPECIAL TOOLS ............................77 T1 ................................
  • Page 7 NORMAL DIFFERENTIAL UNIT ......................125 EXPLODED VIEW ............................125 DISASSEMBLY ............................. 126 ASSEMBLY ..............................128 SPECIAL TOOLS ............................131 T1 ................................131 T2 ................................131 T3 ................................132 T4 ................................132 LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) ..............133 EXPLODED VIEW ............................
  • Page 8 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 9: Introduction

    INTRODUCTION The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient re- pair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a com- plete overhaul of the unit.
  • Page 10 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 11: Specifications

    SPECIFICATIONS DEFINITION OF VIEWPOINTS DATA PLATE MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY Model number Serial number Lubricant ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 12: Conversion Tables

    CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE 1 ATM=1 BAR=105 PA=14.4 PSI UNIT OF WEIGHT 0,001 0,102 0,225 1daN 0,01 1,02 2,25 1000 9,81 0,981 0,00981 2,205 UNITS OF TORQUE N·m daN·m kN·m kg·m lb·in 1N·m 0,001 0,102 8,854 1daN·m 0,01 1,02 88,54...

  • Page 13: Torque Specifications

    TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270 M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 –...

  • Page 14: Wheel Nut Tightening Torques

    TORQUE SPECIFICATIONS WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended from rim's O.E.M. with reference the the quality of the rim's material. WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY ST 37 **ST 52 M18X1,5 mm 330 N·m...

  • Page 15: Maintenance

    MAINTENANCE MAINTENANCE MAINTENANCE POINTS Oil fill plug Oil drain plug Check level plug ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 16: Maintenance Intervals

    MAINTENANCE MAINTENANCE INTERVALS OPERATION MEMBER FREQUENCY LUBRICANTS Differential Monthly SAE85W90 (API GL4 - MIL L-2105) Check levels With additives for oil-bath brakes Planetary reduction Every 200 hours Differential Every 800 hrs * SAE85W90 (API GL5 - MIL 2105-B) With additives for oil-bath brakes, for units Oil change Planetary reduction Every 1000 hrs *...

  • Page 17: Lubricant & Sealant Specifications

    MAINTENANCE LUBRICANT & SEALANT SPECIFICATIONS 1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor. 2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar products marketed by different brand names with different trade marks.
  • Page 18 MAINTENANCE Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 19: Safety Precautions

    SAFETY PRECAUTIONS During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts mentioned should rest on supporting benches. When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm. When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po- sitioned and that the machine is locked lengthways.
  • Page 20 MAINTENANCE Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 21: Checking Wear And Replacing The Braking Discs

    CHECKING WEAR AND REPLACING THE BRAKING DISCS EXPLODED VIEW MAXIMUM 10° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 22: Disassembly

    DISASSEMBLY DISASSEMBLY CAUTION Perform all operations on both arms. FIGURE 3: Remove the swinging support (2) on the side op- posite the drive. NOTE: If the bushing (17) is worn and needs replacing, write down the assembly side of the connection notch "A". FIGURE 1: Remove the oil-level plug (1).
  • Page 23 DISASSEMBLY FIGURE 6: Remove the arm (3) together with the pack of the braking disks (7). FIGURE 9: Remove the pin screws (10) guiding the piston (9). Place the arm on a bench. CAUTION If the screws are to be replaced, write down the different co- lors for the different brake gap.

  • Page 24: Assembly

    ASSEMBLY ASSEMBLY FIGURE 13: Lubricate the seals (11) and (12) and fit the piston (9) into the arm (3). FIGURE 11: Accurately clean the piston (9) and the seats of slide and seal. CAUTION Replace the o-rings (11) and (12) and the anti-extrusion rings (13) and (14);...
  • Page 25 ASSEMBLY NOTE: When installing the steel discs, the slot corresponding to the oil level cap should always be kept free. FIGURE 15: Fit the pin screws (10) making sure that they are all of the same color. See Service Part List “Brake” section for bolt color detail. Apply Loctite 270 to the thread.

  • Page 26: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 2313 2305 P/N: Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 27: Complete Steering Case

    COMPLETE STEERING CASE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 28: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 1: Loosen and remove the capscrews (15)(8) from the articulation pin (19)(4). FIGURE 4: Remove the complete steering case (1). FIGURE 2: Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3). CAUTION Pay attention not to damage the surfaces.

  • Page 29: Assembly

    ASSEMBLY ASSEMBLY FIGURE 8: Lubricate steering case. FIGURE 5: Lubricate the terminal of the u-joint and install the steering case (1). CAUTION Pay due attention not to damage the dust cover rings and the sealing rings. FIGURE 9: Fit the unit (19) in the steering case (1). Position the screws (15) and tighten.
  • Page 30 ASSEMBLY FIGURE 11: Check with a lever that there is no vertical gap. In case there is any gap, determine the width and reduce it by removing shims. 30 - 60 N·m FIGURE 12: Check the torque of the pins, which has to be between 30 and 60 N·m.

  • Page 31: Double U-Joint

    DOUBLE U-JOINT EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 32: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Position the entire u-joint (4) under a press and re- move the complete bushing (13). FIGURE 1: Loosen and remove the top and bottom check nuts (2) from the studs (3). FIGURE 5: Remove the snap ring (10) from the bearing (11). Use a puller to remove the bearing (11), the sealing ring (12) and the o-ring (14).

  • Page 33: Assembly

    ASSEMBLY ASSEMBLY FIGURE 9: Fit the check ring (9) on the bushing unit (13); also put the o-ring (14) into position. FIGURE 6: Using tools T1 (See drawing T1 p. 33) and T2 (See drawing T2 p. 33), insert the sealing ring (12) and the bearing (11) in the bushing (13).
  • Page 34 ASSEMBLY FIGURE 12: Install the nuts (3) on the studs (2) and tighten them using a torque wrench. Torque wrench setting: 122 N·m Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 35: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3342 -- 0.1 Ø54,5 Ø30 + 0.1 Ø54 Ø79 -- 0.15 Ø90 P/N: 2301 x45 ° Proteggere da cementazione x45 ° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 36 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 37: Planetary Reduction Gear

    PLANETARY REDUCTION GEAR EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 38: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Remove the snap rings (9). FIGURE 1: Disconnect the steering bars from the steering case (3). For details, see COMPLETE STEERING CASE p. 25. Remove the securing screws (1) from the planetary carrier co- ver (2). FIGURE 5: With the help of a puller, remove the planetary wheel gears (10).
  • Page 39 DISASSEMBLY FIGURE 7: Remove the safety flange (6). FIGURE 10: Remove the crown flange (5). FIGURE 8: Using a puller, remove the complete crown flange FIGURE 11: Partially extract the hub (7) using a plastic ham- (5) by acting on the stud bolts. mer.
  • Page 40 DISASSEMBLY FIGURE 13: Remove the complete hub (7). FIGURE 16: Remove the external thrust blocks from the be- arings (8) and (15) force a pin-driver into the appropriate slots on the hub (7). NOTE: Hammer in an alternate way so as to avoid clamping or deformation of the thrust blocks.
  • Page 41 DISASSEMBLY FIGURE 18: Remove the pins and remove the steering case (3). For details, see COMPLETE STEERING CASE p. 25. ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 42: Assembly

    ASSEMBLY ASSEMBLY T9 A FIGURE 22: Position the lower part of tool T3A (See drawing T3 p. 45) and the thrust block of the external bearing (8) under the press. FIGURE 19: Lubricate the bushing (18) and the seat of the steering case (3).
  • Page 43 ASSEMBLY FIGURE 25: Fit the bearing (15) into the internal thrust block. FIGURE 28: Install the hub (7). FIGURE 26: Apply a repositionable jointing compound for se- FIGURE 29: Install the external bearing (8). als to the outer surface of the sealing ring (14). Position the sealing ring (14) in the hub (7).
  • Page 44 ASSEMBLY FIGURE 31: Insert the snap ring (12) in order to fix the flange FIGURE 33: Apply Tecnolube Seal 101 grease to the surface (5) in the crown (13). of the safety flange (6) which touches the crown flange (5). Fit the safety flange (6).
  • Page 45 ASSEMBLY FIGURE 36: With the help of tool T5 (See drawing T5 p. 46) FIGURE 39: Lock the planetary carrier cover (2) by tightening insert the planetary wheel gears (10) into the cover (2). the screws (1). Accurately check the orientation. Torque wrench setting for screws: 40 - 50 N·m FIGURE 37: Lock the gears (10) into position by fitting the FIGURE 40: Connect the steering bars.

  • Page 46: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 2303 Proteggere da cementazione x45 ° x15 ° x15 ° -- 0.2 3363 P/N: Proteggere da cementazione x45° x15° -- 0.2 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 47 SPECIAL TOOLS P/N: 3354 Ø158.5 Ø158.5 20° Ø50 H7 Ø35 Ø30 20° Ø40 Ø140 -- 0.08 Ø50 -- 0.12 Ø150 ±0.03 Ø200 Ø95 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 48 SPECIAL TOOLS 3502 P/N: Ø40 Ø139.5 -- 0.1 Ø153 Ø168 Ø180 2304 P/N: x15° x45° 10 15 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 49: Steering Cylinder

    STEERING CYLINDER EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 50: Optical Sensor And Magnetic Sensor

    OPTICAL SENSOR AND MAGNETIC SENSOR OPTICAL SENSOR AND MAGNETIC SENSOR Optical sensor Magnetic sensor Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 51: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Disconnect the tapered pins of the articulation (4) from the steering case (7) by means of a puller. FIGURE 1: Remove the centering sensor (1) of the steering piston (2), if supplied. FIGURE 5: If the connection of the steering bars includes a safety collar (13), raise the border.
  • Page 52 DISASSEMBLY FIGURE 7: Remove the securing screws (8) from the steering FIGURE 10: With the help of a plastic hammer, push the head cylinder (9). (2) inside the cylinder (3). NOTE: The head should line up with the edge of the cylinder. FIGURE 8: Extract the cylinder (9) using a plastic hammer.
  • Page 53 DISASSEMBLY FIGURE 13: Disassemble the cylinder unit (3) by extracting first the head (2), then the piston (5). CAUTION Write the assembly side of the piston (5). The beveled part "A" of the piston is oriented towards the head (2). FIGURE 14: Remove all seals, anti-extrusion rings and scra- per rings from head (2), cylinder (3) and piston (5).

  • Page 54: Assembly

    ASSEMBLY ASSEMBLY FIGURE 17: Fit the seal (9) onto the outside of the head (2). FIGURE 15: After applying grease, install the sealing ring (6) CAUTION of the shaft, the anti-extrusion ring (7) and the scraper ring (8) inside the cylinder (3). 1 - In order to facilitate assembly, apply grease to the outer surface of the piston.
  • Page 55 ASSEMBLY FIGURE 19: Apply tool T1 (See drawing T1 p. 58) to the shaft FIGURE 22: Apply grease to head (2) seals, fit the head onto on the opposite side of the head (2) and center it on the cylin- the piston and push it into the cylinder (3) using a plastic ham- der (3) so that it fits into the piston (5).
  • Page 56 ASSEMBLY FIGURE 28: Apply Loctite 242 to the thread and connect the FIGURE 25: Fit the snap ring (1) on the head (2). steering bars by screwing the terminals onto the piston stem. Torque wrench setting: 240 - 270 N·m CAUTION NOTE: Make sure that the snap ring (1) is securely fastened in its...
  • Page 57 ASSEMBLY CAUTION Eliminate the action of the negative brake, if fitted. T1 2 T1 2 FIGURE 30: OLD VERSION Insert the cotter pins (3) and bend the safety stems. FIGURE 33: Apply tools T2 (See drawing T2 p. 59) to the hubs and lock them.
  • Page 58 ASSEMBLY I max=0,80 A NERO BLACK CONNETTORE CONNECTOR BATTERIA BATTERY BLUE T1 2 T1 2 MARRON E BROWN FIGURE 36: Sensor connection card, OPTIONAL version. FIGURE 39: Without moving the piston, check front and rear size at the edge of tools T2 (See drawing T2 p. 59). Maximum difference: 0.6 - 0.7 mm NOTE: In order to check the rear size, rotate the bevel pinion and...
  • Page 59 ASSEMBLY FIGURE 41: CONVERGENCY ADJUSTMENT ON UNITS FIGURE 44: Hold the articulations still and rotate the ball- WITH COLLAR and-socket joints (15). Loosen the nuts on the collars (12). Once the convergency has been adjusted, lock the nuts (11). Torque wrench setting for nuts: 298 - 328 N·m FIGURE 42: Rotate the ball-and-socket joints (16) until con- vergency has been obtained.

  • Page 60: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 2724 -- 0.05 -- 0.10 Ø45 x1.25 Ø6.5 -- 0.05 Ø20.4 + 0.05 Ø43.6 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 61 SPECIAL TOOLS P/N: 1867 ±0.1 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 62 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 63: Differential Unit

    DIFFERENTIAL UNIT EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 64: Disassembly

    DISASSEMBLY DISASSEMBLY T1 3 FIGURE 4: Apply tool T1 (See drawing T1 p. 66) and remove the ring nuts. FIGURE 1: Remove the complete arms. NOTE: For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19. Accurately clean the threaded portions on ring nuts of body and cover.
  • Page 65 DISASSEMBLY FIGURE 7: If the bearings need replacing, extract the external thrust blocks of the bearings (7) and (8) from middle cover and central body. NOTE: Accurately check the o-ring (6). FIGURE 8: Remove the top plug (7). NOTE: The cap must be replaced each time the unit is disassem- bled.

  • Page 66: Assembly

    ASSEMBLY ASSEMBLY FIGURE 11: Lock the middle cover (5) with screws (4). Torque wrench setting for screw: 23.8 - 26.2 N·m FIGURE 9: If the bearings are replaced, insert the external thrust blocks in the middle cover (5) and in the central body (2).
  • Page 67 ASSEMBLY FIGURE 17: Difference between MIN and MAX clearance for FIGURE 14: Introduce a dial indicator with rotary key "A" whole circumference should not exceed 0.09 mm. through the top plug hole (7). Position the dial indicator on the center of one of the teeth of the crown, pre-set it to 1mm and reset it.

  • Page 68: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3333 x15 ° x15 ° 3317/4 P/N: 5x15 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 69: Bevel Pinion

    BEVEL PINION EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 70: Disassembly

    DISASSEMBLY DISASSEMBLY T20A ( T20B ) (T1B) FIGURE 3: Position tool T1A (See drawing T1 p. 77) (or T1B), so as to avoid pinion rotation. Loosen and remove the nut (1); also remove the o-ring (3). FIGURE 1: Remove the complete arms and the differential unit.
  • Page 71 DISASSEMBLY FIGURE 6: Remove the sealing ring (6). FIGURE 9: Remove the pinion (8), shims (11) and spacer (10). T2 1 T2 2 FIGURE 7: Position wrench T3 (See drawing T3 p. 78) onto the ring nut (7) and apply bar hold T2 (See drawing T2 p. 78). to the pinion (8).
  • Page 72 DISASSEMBLY FIGURE 12: Insert a drift in the appropriate holes and remove the thrust block of the internal bearing (9) as well as the shim washers (14). Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 73: Assembly

    ASSEMBLY ASSEMBLY T25C T2 4 T25A FIGURE 15: Partially insert the thrust block of the external be- aring (13). FIGURE 13: Using a surface plate, reset a dial indicator "DG" and place it on the measurement ring T5 (See drawing T5 p.
  • Page 74 ASSEMBLY T26C T26C T2 4 T26B T26B 30. 2 (61-A)+1 15+30.2=B FIGURE 21: Calculate size "B" which will be the first useful FIGURE 18: Insert tool T7B (See drawing T7 p. 81) complete value for calculating the size of the shims (14) that are to be with external bearing (13), measurement ring T5 (See drawing inserted under the thrust block of the internal bearing (9).
  • Page 75 ASSEMBLY B-C=S T26C T26B FIGURE 24: Calculate the difference between sizes "B" and FIGURE 27: Position tools T7C (See drawing T7 p. 81) and "C" so as to obtain the size "S" of the shim (14) that will go T7B (See drawing T7 p. 81) complete with tapered bearings under the thrust block of the internal bearing (9).
  • Page 76 ASSEMBLY DD G T26C T26B FIGURE 30: Insert depth gauge "DDG" into tool T7B (See FIGURE 33: Fit the pinion (8), shim "S1" (11) and spacer (10) drawing T7 p. 81) T7C (See drawing T7 p. 81) and measure in the main body (12). variation "H"...
  • Page 77 ASSEMBLY CAUTION STANDARD INPUT FLANGE VERSION If torque exceeds the maximum value, then the size of shim "S1" (11) between the bearing (13) and the spacer (10) ne- eds to be increased. If torque does not reach the set value, increase the torque setting of the ring nut (7) in different stages to obtain a ma- ximum value of 570 N·m.
  • Page 78 ASSEMBLY T1 9 FIGURE 43: Fit the flange (2) complete with the guard (4) and FIGURE 41: FLANGED GEARBOX VERSION fasten it. Apply onto the pinion (8) the bar-hold and with the help of a tor- For seating the flange (2), use a plastic hammer if necessary. que wrench, check the torque of the pinion (8).

  • Page 79: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 2308 ± 0.2 Ø185 ± 0.2 Ø105 -- 0 Ø34.5 + 0.2 Ø50 ±0.5 Ø32 Ø45 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 80 SPECIAL TOOLS 3317/3 P/N: 3317/A P/N: Ø85 Ø66 Ø55H7 15° Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 81 SPECIAL TOOLS P/N: 2309 99.5 2310 P/N: ± 0.001 Ø30.2 5X45° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 82 SPECIAL TOOLS 3329/3 P/N: Ø83 Ø35 -- 0.08 Ø19.5 -- 0.12 Ø19.55H7 Ø40 Ø88 + 0.1 Ø20 -- 0 Ø55 Ø83 -- 0.08 Ø89 -- 0.12 -- 0.1 Ø16.5 -- 0.2 M18x1.5 M18x1.5 Ø40 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 83 SPECIAL TOOLS P/N: 2312 Ø110 Ø20 Ø65 Ø41.2 Ø20 -- 0.03 Ø9 Ø6.5 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 84 SPECIAL TOOLS 3354 P/N: 5x15 3327 P/N: Ø50 + 0.08 + 0.12 Ø37.75 -- 0.2 -- 0.3 Ø55 Ø89 Ø99 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 85: Manual Emergency Relase

    MANUAL EMERGENCY RELASE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 86: Release

    RELEASE RELEASE DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. FIGURE 3: Using a wrench, tighten the screws (31) in an al- ternate sequence by 1/4 turn at a time so as to compress the Belleville washers (1) and disengage the braking disks.

  • Page 87: Adjust

    ADJUST ADJUST Tecno Lube 101 FIGURE 4: Remove screws complete with nuts and seals. Replace seals, apply silicone-based Tecno Lube /101 grease to the screws and install all parts into the arm. 34 mm FIGURE 5: Adjust screws (31) to obtain a distance of 34 ± 0.5 mm between axle machined surface and screw underhead.
  • Page 88 ADJUST Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 89: Mechanical Parking Brake

    MECHANICAL PARKING BRAKE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 90: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. NOTE: Though the photos in this manual refer to a steering and 12 13 oscillating axle, the operations described apply anyway.
  • Page 91 DISASSEMBLY FIGURE 6: Remove the braking disks (9) and the whole piston (10). For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19. FIGURE 7: If pins (11) need replacing, block the piston (10) into a vice whose jaws are covered in smooth material and re- move the pins.

  • Page 92: Assembly

    ASSEMBLY ASSEMBLY FIGURE 12: Install the arms (8) into the main body; check flat- 12 13 ness and block arms following the appropriate procedures il- lustrated in section MECHANICAL PARKING BRAKE p. 87 FIGURE 9: Install thrust levers (12) and (13), then install the and HYDRAULIC NEGATIVE BRAKE p.
  • Page 93 ASSEMBLY CAUTION The idle stroke should be eliminated without preloading thrust levers (12) and (13). FIGURE 18: After connecting the control cable, check that when brakes are released both studs (16) do lean against bu- shing (6). FIGURE 15: Connect the braking circuit and apply maximum working pressure to set the disks.
  • Page 94 ASSEMBLY Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 95: External Hydraulic Negative Brake

    EXTERNAL HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 96: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. FIGURE 3: Release the pressure in the cylinder and discon- nect the pressure delivery tube.

  • Page 97: Assembly

    ASSEMBLY ASSEMBLY FIGURE 9: Install cylinder (4) complete with rod (5) and inter- nal nut (6). FIGURE 6: Install spacer (2) and insert the pin of support (8) into the right-hand braking lever. Fit the second spacer (2) and snap ring (1). FIGURE 10: Center the hole of fulcrum pin (3) and washers (12).
  • Page 98 ASSEMBLY 4 √ 5 mm FIGURE 12: Check that, when the brakes are released (pres- sure inserted), levers (19) lean against the screws (18) without pre-stressing them and make sure that a clearance "A" is left between cylinder (4) and lever (19). Also check that when pressure is released, piston (13) projects out by 4 - 5 mm.

  • Page 99: External Hydraulic Negative Brake With Quick Release

    EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 100: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. FIGURE 3: Remove the fulcrum pin (3) from the cylinder (4) complete with washers (22).
  • Page 101 DISASSEMBLY 15 16 FIGURE 6: Remove snap ring (8) and washer (9) and separate FIGURE 9: Slowly release nut "B" and disassemble the check support (10) and second washer (9) from the check unit (7). unit. FIGURE 7: Introduce an M14x100 screw "A" into the hole of FIGURE 10: Loosen nut (17) and remove stem (6) from the the check unit (7) and screw a nut "B"...

  • Page 102: Assembly

    ASSEMBLY ASSEMBLY FIGURE 14: Fit the safety snap ring (5) onto the stem (6). FIGURE 11: Screw stem (6) into the piston without locking CAUTION the nut (17). In case the braking disks have been replaced or if brake pi- stons have been removed: before adjusting the negative 15 16 braking unit, apply the brakes several times at maximum...
  • Page 103 ASSEMBLY FIGURE 16: Fit the spacer (2) and insert the pin of support FIGURE 19: Introduce pressure into the cylinder (4) and, with (10) in the right-hand braking lever. Fit the snap ring (1). the levers (28) resting against the adjustment studs (27), screw rod (6) to engage the quick release (7) in the slot.
  • Page 104 ASSEMBLY FIGURE 22: Release the check unit (7) by giving a hammer blow to the external ring. Introduce pressure again and check that at the end of piston stroke, the check unit (7) is actually engaged onto the rod (6). Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 105: Incoming Drum Brake

    INCOMING DRUM BRAKE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 106: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. FIGURE 3: Remove the shoe assembly (4). If necessary, remove the snap ring (5) and pull out the lever (6).
  • Page 107 DISASSEMBLY FIGURE 6: Remove parts in the following sequence: nut (9), FIGURE 9: Remove brake support (14). o-ring (11), flange (10) and stop ring (7). FIGURE 10: Remove the spacer (15). FIGURE 7: Remove the seal (12) and discard it. NOTE: NOTE: If operations are to be carried out the bevel pinion, see...

  • Page 108: Assembly

    ASSEMBLY ASSEMBLY T2 7 FIGURE 14: Lubricate the outer part of the seal (12) and insert it into the brake support (14) using tool T2 (See drawing T2 p. 109). FIGURE 11: Fit the spacer (15) onto the pinion (16). NOTE: Carefully check assembly direction.
  • Page 109 ASSEMBLY FIGURE 17: Insert the screws (8) and hold them in position FIGURE 20: Fit the drum (1). with the snap ring (7). NOTE: NOTE: Make sure that the friction surface of the drum carries no Make sure that the ring is properly set in its seat. trace of grease and is perfectly clean.

  • Page 110: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 2308 ± 0.2 Ø185 ± 0.2 Ø105 -- 0 Ø34.5 + 0.2 Ø50 ± 0.5 Ø32 Ø45 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 111 SPECIAL TOOLS P/N: 3327 Ø50 + 0.08 + 0.12 Ø37.75 -- 0.2 -- 0.3 Ø55 Ø89 Ø99 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 112 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 113: 4" Incoming Brake (2 And 3 Function Versions)

    4" INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS) EXPLODED VIEW FUNCTION VERSION 20 21 RKZA 0040 3-FUNCTION VERSION ONLY ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 114: Disassembly

    DISASSEMBLY DISASSEMBLY NOTE: If disassembly is awkward, heat nut (3) about 176 F° DANGER (80C°). Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle.
  • Page 115 DISASSEMBLY NOTE: CAUTION Thoroughly clean the face of bevel pinion support where the hub rests, check the o-ring (24) and replace it if ne- Hold piston (12) as it may be rapidly ejected and damaged. cessary. 25 26 FIGURE 7: Remove check screws (17) from cylinder (18). FIGURE 10: Remove friction discs (25), (26) and hub (27).
  • Page 116 DISASSEMBLY CAUTION Hold piston (33) as it may be rapidly ejected and damaged. FIGURE 12: 3-FUNCTION VERSION ONLY Loosen and remove the pin-type screws (31). NOTE: Loosen screws (31) in an alternate and criss-cross me- thod. FIGURE 15: 2-FUNCTION VERSION ONLY Remove the spacer (39).
  • Page 117 DISASSEMBLY NOTE: Sealing rings (13) and (15) and anti-extrusion rings (14) and (16) must be replaced each time the unit is disassem- bled. 36 37 FIGURE 20: BRAKING DISCS PACK CONTENTS The braking discs pack is comprised of: 11 braking discs and 12 steel counterdiscs.

  • Page 118: Assembly

    ASSEMBLY ASSEMBLY T3 1 35 34 36 37 36 37 FIGURE 25: Lubricate sealing ring (38) and, using tool T1 (See drawing T1 p. 122), fit it into the cover (8). FIGURE 23: 3-FUNCTION VERSION ONLY NOTE: Fit the sealing rings (34), (36) and the anti-extrusion rings (35), (37) onto the piston (33) of the service brake.
  • Page 119 ASSEMBLY FIGURE 30: 3-FUNCTION VERSION ONLY FIGURE 28: 3-FUNCTION VERSION ONLY Insert springs (32) for piston (33) backward movement. Using the measurements just taken, calculate thickness "S" of shims (9) as follows: S=(A1+1.5)±(B1+18.4) where: S=Shim thickness - 1.5 mm=fixed measure of braking discs clearance - 18.4 mm=fixed measure of Belleville washers.
  • Page 120 ASSEMBLY FIGURE 33: Lubricate seals (13), (15) and fit the piston (12) FIGURE 36: Lubricate the o-ring (24) and fit cylinder (18) into the cylinder (18). Engage piston on the pin (19). complete with piston (12). For the assembly, use a plastic hammer and push the piston (12) to end of stroke.
  • Page 121 ASSEMBLY FIGURE 39: 2-FUNCTION VERSION ONLY FIGURE 42: Fit the Belleville washers (11) onto the cover (8), Fit the separating ring (10) of Belleville washers onto the cover thoroughly checking washers orientation. (8), measure size "B" and note it down. Measure size "A"...
  • Page 122 ASSEMBLY NOTE: Check that pressure is kept stable for at least 5 minutes and make sure there are no leaks. FIGURE 45: Apply Loctite 242 to the threaded portion of the pinion, fit o-ring (4) and nut (3). Tighten the nut with a torque 29 30 wrench set to 280 - 310 N·m.
  • Page 123 ASSEMBLY FIGURE 50: Fit the electronic sensor (1) and screw it up to the FIGURE 52: When the emergency is over, loosen the studs in limit stop. Unscrew sensor by 3/4 turn and lock into position an alternate manner until a 17 mm projection is obtained; lock with nut.

  • Page 124: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3739 Ø50 + 0.2 Ø64 Ø84.5 Ø94.5 Ø110 3317/3 P/N: Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 125 SPECIAL TOOLS P/N: 3317/A Ø85 Ø66 Ø55H7 15° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 126 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 127: Normal Differential Unit

    NORMAL DIFFERENTIAL UNIT EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 128: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: If the bearing need replacing, extract the bearing (4) from the differential carrier (12). FIGURE 1: Remove the capscrews (1) from the crown (2). 6 11 FIGURE 5: Remove the snap rings (11) from the two pins (9) of the planetary gears (7).
  • Page 129 DISASSEMBLY 5 12 FIGURE 7: Force tool T1 (See drawing T1 p. 131) in-between the planetary gears (7) using two pin-drivers. FIGURE 10: Remove tool T1 (See drawing T1 p. 131) together with the pin (9) of the planetary gear. CAUTION Make sure that tool T1 (See drawing T1 p.

  • Page 130: Assembly

    ASSEMBLY ASSEMBLY T1 4 T16C FIGURE 16: Insert tool T1 (See drawing T1 p. 131) between the two planetary gears (7). Line up the entire unit by pushing bar T3C (See drawing T3 p. 132) all the way down until press FIGURE 13: Insert the shim washer (5) and the differential tool T3A (See drawing T3 p.
  • Page 131 ASSEMBLY T1 5 FIGURE 22: Remove press tool T3B (See drawing T3 p. 132), bushing T2 (See drawing T2 p. 131) and fit the snap ring (11) FIGURE 19: Place the differential carrier (12) under the press, position guide bushing T2 (See drawing T2 p. 131) and insert on the pin (9).
  • Page 132 ASSEMBLY FIGURE 25: Position the crown (2) on the differential carrier (12) and lock it with screws (1) applied with Loctite 242. Torque wrench setting for screws: 128 - 142 N·m NOTE: Secure the screws using the criss-cross method. T1 7 T1 7 FIGURE 26: Install the bearings (3) and (4) using tool T4 (See drawing T4 p.

  • Page 133: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3708 x45 ° Ø5.5 x45 ° 10.5 22.5 Ø5.5 P/N: 3424 0.0.1 24.5 15 ° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 134 SPECIAL TOOLS 2306 P/N: x30° 2x30° ± 0.1 46.45 ± 0.5 19.6 56.6 29.6 x45° x30° P/N: 3332 x45° Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 135: Limited Slip Differential Unit (25% And 45%)

    LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 136: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Remove the planetary gear (6) and the whole fric- tion unit (7). FIGURE 1: Remove the whole differential unit (2) from the central axle unit (1). For details, see DIFFERENTIAL UNIT p. 61. FIGURE 5: If bearing (8) needs replacing, extract it from the differential unit (9).
  • Page 137 DISASSEMBLY T16A T1 4 T1 5 FIGURE 7: Introduce tool T1 (See drawing T1 p. 140) in- FIGURE 10: Remove press tool T3A (See drawing T3 p. 141) between the planetary gears (12). and bushing T2 (See drawing T2 p. 140). NOTE: In this state, the pin (11) is contained within tool T1 (See drawing T1 p.
  • Page 138 DISASSEMBLY FIGURE 13: Remove tool T1 (See drawing T1 p. 140) and ex- tract from the differential unit (9) the two final planetary gears (12), the 2nd differential side gear (6) and the whole friction assembly concerned (7). Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 139: Assembly

    ASSEMBLY ASSEMBLY 18, 2 ± 0,1 FIGURE 16: 45% FRICTION UNIT COMPOSITION Friction ring with inner disc (13), intermediate discs (14) and friction discs (15) alternated, outer disc (16) and spacer (17). FIGURE 14: Place the friction disc assembly (7) - suitable for the specific type of slipping and differential side gear (6) into the differential unit (9).
  • Page 140 ASSEMBLY T1 4 T1 5 T16C FIGURE 19: Insert tool T1 (See drawing ) in-between the two FIGURE 22: Position the differential unit (9) under the press, planetary gears (12). position bushing T2 (See drawing T2 p. 140) and insert the Align the whole unit, pushing bar T3C (See drawing T3 p.
  • Page 141 ASSEMBLY FIGURE 25: Remove press tool T3B (See drawing T3 p. 141), FIGURE 27: Line the lubrication holes up with the slots in the bushing T2 (See drawing T2 p. 140) and fit the snap ring (10) differential carrier. Orient the holes of the crown (4) towards onto the pin (11).

  • Page 142: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3708 x45 ° Ø5.5 x45 ° 10.5 22.5 Ø5.5 3424 P/N: 0.0.1 24.5 15 ° Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 143 SPECIAL TOOLS P/N: 2306 x30° 2x30° ± 0.1 46.45 ± 0.5 19.6 56.6 29.6 x45° x30° P/N: 3332 x45° ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 144 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 145: Hydraulic Differential Lock

    HYDRAULIC DIFFERENTIAL LOCK EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 146: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Loosen the lock nut (4) of selector fork (5) by ap- proximately 2 turns. FIGURE 1: Remove the arms. For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19. FIGURE 5: Using a metal punch and a hammer, disengage selector fork (5) from piston cone (6).
  • Page 147 DISASSEMBLY FIGURE 7: Remove screws (14) and remove the intermediate FIGURE 10: Remove snap ring (12) and whole piston (6). cover (13). NOTE: Support the differential unit with a lever. FIGURE 11: Remove guide ring (11) and o-ring (10). NOTE: The guide ring (11) and o-ring (10) must be replaced each FIGURE 8: Disconnect selector (5) from piston (6).
  • Page 148 DISASSEMBLY FIGURE 13: Remove bearing (16) from the differential carrier (17) as well as the stop ring (18), the sleeve (19) and the sphe- res (20). NOTE: Write down the direction of assembly of the stop ring (18). FIGURE 14: ONLY IF NECESSARY Remove the key (21) and disassemble the differential unit (15).

  • Page 149: Assembly

    ASSEMBLY ASSEMBLY T2 9 FIGURE 18: Fit o-ring (10) and guide ring (11) onto the piston (6). Lubricate seals and insert the assembly into tool T1 (See FIGURE 15: ONLY IF PREVIOUSLY DISASSEMBLED drawing T1 p. 149). Assemble the differential unit (15). (For details, see DIFFEREN- TIAL UNIT p.
  • Page 150 ASSEMBLY T3 0 FIGURE 21: Screw tool T2 (See drawing T2 p. 149) on the th- FIGURE 24: Install the intermediate cover (13) and lock it with read of the piston (6) to compress the spring (7) and vacate screws (14). Tighten screws using a torque wrench setting of the seat for installing the snap ring (12).

  • Page 151: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS P/N: 3543 -- 0.08 Ø28 -- 0.12 -- 0.08 Ø24 -- 0.12 5° Ø26 Ø33 P/N: 2316 M12x1.25 Ø16.2 -- 0.1 + 0.2 Ø17 + 0.1 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 152 SPECIAL TOOLS Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 153: Hydraulic Negative Brake

    HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 154: Disassembly

    DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equip- ment Manufacturer (OEM) manual that came with the vehi- cle. FIGURE 3: Remove arm together with brakes and axle shafts; lay down the arm vertically.
  • Page 155 DISASSEMBLY FIGURE 6: Write down their order of assembly and remove FIGURE 9: Move the cover (7) outwards. the counterwasher (11). FIGURE 10: Remove the Belleville washers (2) and write down direction of assembly. FIGURE 7: Loosen the studs and remove two of them. FIGURE 11: Slowly introduce low-pressure compressed air FIGURE 8: Loosen the studs and remove two of them.
  • Page 156 DISASSEMBLY NOTE: The o-rings must be replaced each time the unit is disas- sembled. FIGURE 14: Remove brake discs (14) and (15), writing down direction of assembly. NOTE: If disks are not to be replaced, avoid changing their position. FIGURE 12: Write down their order of assembly and mark and remove negative piston sign the position.

  • Page 157: Assembly

    ASSEMBLY ASSEMBLY FIGURE 16: Fit o-rings (4)(28)(27)(5)(6) onto the piston (3). Lubricate the piston and the o-rings and install the unit into the cylinder (7). FIGURE 19: Using a plastic hammer, insert the piston (10) into the cylinder (7). NOTE: Lightly hammer all around the edge in an alternate FIGURE 17: Using a plastic hammer, insert the piston (3) into sequence.
  • Page 158 ASSEMBLY FIGURE 24: Lock the cylinder. FIGURE 21: Apply grease and position the Belleville washers (2) and engage the cylinder (1). 30 - 45 N·m NOTE: Check the sense of direction of washers (2) and relative centering. FIGURE 25: Tightening the studs with a torque wrench set to a torque of 30 - 45 N·m.
  • Page 159 ASSEMBLY FIGURE 30: Fit the reversal springs (12)(13) on the piston (11). FIGURE 27: Connect an external pump to the negative brake and introduce pressure to 15 - 30 bar. 10 - 15 N·m FIGURE 31: Apply LOCTITE 270 to the thread of the pistion adjustment nut.
  • Page 160 ASSEMBLY 5 - 7 N·m FIGURE 33: Fit the pin screws making sure that they are all FIGURE 36: Arm fix quote = 68 mm of the same color. Apply Loctite 270 to the thread. Torque wrench setting: 5 - 7 N·m. FIGURE 37: S = 68 mm - ( x + y + v ) = Thickness of shims to insert under the shim washer.
  • Page 161 ASSEMBLY FIGURE 38: Slightly lubricate the braking disks (14) and fit FIGURE 40: Torque wrench setting: them in the arm following the correct sequence; orient them A = 200 N·m so that the oil circulation holes and the marks “B” are lined B = 283 N·m When installing the steel discs, the slot corresponding to the NOTE:...
  • Page 162 ASSEMBLY Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...

  • Page 163: Incorporated Reduction Gear And Pinion 602

    INCORPORATED REDUCTION GEAR AND PINION 602 EXPLODED VIEW ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...

  • Page 164: Disassembly

    DISASSEMBLY DISASSEMBLY FIGURE 4: Remove the upper flange (1) together with dust ring (5). FIGURE 1: The figure shows the axle with incorporated re- duction gear with Mechanic flanges; disassembly and as- sembly procedures also apply to DIN flanges. FIGURE 5: Remove the snap ring (6) and discard it. FIGURE 2: Loosen the check nuts on upper (1) and lower (2) flange.
  • Page 165 DISASSEMBLY FIGURE 7: Remove check screws (7), (8) and relative wa- FIGURE 10: Lightly tap with a hammer to disengage cover (9) shers (10) from cover (9). from upper gear (12). FIGURE 8: In turn, insert a punch in the slots provided and, FIGURE 11: Draw out cover (9) and remove any sealant left.
  • Page 166 DISASSEMBLY FIGURE 13: Remove upper gear assembly (12) complete with FIGURE 16: Remove outer bearing (14) and spacer (16). bearings (14). FIGURE 17: Disjoin from the steering case the steering bar lo- FIGURE 14: Using a puller, remove snap ring (15) from cover cated by the side of the intermediate cover (17).
  • Page 167 DISASSEMBLY FIGURE 22: Using a puller, extract pinion (20) complete with FIGURE 19: Heat the ring nut (19) at approx. 80°C. inner bearing (21), spacer (22) and distance washers. NOTE: The thrust blocks of the bearings remain in the central body (11).

  • Page 168: Assembly

    ASSEMBLY ASSEMBLY FIGURE 27: With tools T4C (See drawing T4 p. 172), T4D (See drawing T4 p. 172) and T4B (See drawing T4 p. 172) connected to a press, insert the complete pinion assembly FIGURE 25: Find the value of the distance washers (23) and (20).
  • Page 169 ASSEMBLY CAUTION If the crown has been replaced, reinstate clearances. T3 2 T3 2 For details, see DIFFERENTIAL UNIT p. 61. FIGURE 32: Grease snap rings (15) and (6); position the snap rings in the cover (9) using tool T5 (See drawing T5 p. 173). FIGURE 30: Re-install the complete arm checking flatness and blocking the arm by keeping to the appropriate procedu- res illustrated in section CHECKING WEAR AND REPLACING...
  • Page 170 ASSEMBLY T20A (T6B) ( T20B ) FIGURE 35: Apply Loctite 510 to the locking surface of the FIGURE 38: Apply tool T6A (See drawing T6 p. 174) (or T6B) body of the reduction gear (11). to flanges (1) and (2) and tighten nuts (3) using a dynamome- Lubricate snap rings (6) and (15);...

  • Page 171: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Ø75 – 0.08 Ø55 – 0.12 32,25 3/4" Ø15H7-n6 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 172 SPECIAL TOOLS Ø85 Ø66 Ø55H7 15° Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 173 SPECIAL TOOLS Ø64 Ø25 Ø35 -- 0.1 -- 0.2 Ø50 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 174 SPECIAL TOOLS 3x15° 5x15° 17min. Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 175 SPECIAL TOOLS Ø30 -- 0.2 -- 0.3 Ø55 Ø60 -- 0.2 -- 0.3 Ø72 ASM-0025E - 212 Axle Service Manual Dana Holding Corporation...
  • Page 176 SPECIAL TOOLS ± 0.2 Ø185 ± 0.2 Ø105 -- 0 Ø34.5 + 0.2 Ø50 ±0.5 Ø32 Ø45 Dana Holding Corporation ASM-0025E - 212 Axle Service Manual...
  • Page 178 Copyright 2013 Dana Holding Corporation For product inquiries or support, All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445 be reproduced in whole or in part by any means, For other service publications, electronic or otherwise, without prior written approval.
  • Page 180 McConnellsburg PA. 17233-9533 Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Antonia Martins Luiz, 580 Bentley House Z.I. de Baulieu 11 Bolwarra Road Distrito Industrial João Narezzi...

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