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DANA SPICER AXLE 212, Service Manual

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Dana Holding Corporation

ASM-0025E - 212 Axle Service Manual

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  ......................................................................................................................... 13
MAINTENANCE INTERVALS  ................................................................................................................... 14
ADJUSTMENT AND CHECKS  ................................................................................................................. 14
LUBRICANT & SEALANT SPECIFICATIONS ........................................................................................... 15

SAFETY PRECAUTIONS  ................................................................................................................... 17

CHECKING WEAR AND REPLACING THE BRAKING DISCS  ........................................................ 19

EXPLODED VIEW .......................................................................................................................................... 19
DISASSEMBLY ............................................................................................................................................. 20
ASSEMBLY ................................................................................................................................................... 22
SPECIAL TOOLS  .......................................................................................................................................... 24

T1 ............................................................................................................................................................. 24
T2 ............................................................................................................................................................. 24

COMPLETE STEERING CASE .......................................................................................................... 25

EXPLODED VIEW .......................................................................................................................................... 25
DISASSEMBLY ............................................................................................................................................. 26
ASSEMBLY ................................................................................................................................................... 27

DOUBLE U-JOINT  ............................................................................................................................. 29

EXPLODED VIEW .......................................................................................................................................... 29
DISASSEMBLY ............................................................................................................................................. 30
ASSEMBLY ................................................................................................................................................... 31
SPECIAL TOOLS  .......................................................................................................................................... 33

T1 ............................................................................................................................................................. 33
T2 ............................................................................................................................................................. 33

PLANETARY REDUCTION GEAR  .................................................................................................... 35

EXPLODED VIEW .......................................................................................................................................... 35
DISASSEMBLY ............................................................................................................................................. 36
ASSEMBLY ................................................................................................................................................... 40
SPECIAL TOOLS  .......................................................................................................................................... 44

T1 ............................................................................................................................................................. 44
T2 ............................................................................................................................................................. 44
T3 ............................................................................................................................................................. 45
T4 ............................................................................................................................................................. 46
T5 ............................................................................................................................................................. 46

STEERING CYLINDER  ...................................................................................................................... 47

EXPLODED VIEW .......................................................................................................................................... 47
OPTICAL SENSOR AND MAGNETIC SENSOR ............................................................................................ 48
DISASSEMBLY ............................................................................................................................................. 49
ASSEMBLY ................................................................................................................................................... 52
SPECIAL TOOLS  .......................................................................................................................................... 58

T1 ............................................................................................................................................................. 58
T2 ............................................................................................................................................................. 59

Summary of Contents for SPICER AXLE 212

Page 1: ...Service Manual Axle 212 October 2013 ASM 0025E...

Page 2: ......

Page 3: ...TIONS 15 SAFETY PRECAUTIONS 17 CHECKING WEAR AND REPLACING THE BRAKING DISCS 19 EXPLODED VIEW 19 DISASSEMBLY 20 ASSEMBLY 22 SPECIAL TOOLS 24 T1 24 T2 24 COMPLETE STEERING CASE 25 EXPLODED VIEW 25 DISA...

Page 4: ...D VIEW 83 RELEASE 84 ADJUST 85 MECHANICAL PARKING BRAKE 87 EXPLODED VIEW 87 DISASSEMBLY 88 ASSEMBLY 90 EXTERNAL HYDRAULIC NEGATIVE BRAKE 93 EXPLODED VIEW 93 DISASSEMBLY 94 ASSEMBLY 95 EXTERNAL HYDRAUL...

Page 5: ...LODED VIEW 133 DISASSEMBLY 134 ASSEMBLY 137 SPECIAL TOOLS 140 T1 140 T2 140 T3 141 T4 141 HYDRAULIC DIFFERENTIAL LOCK 143 EXPLODED VIEW 143 DISASSEMBLY 144 ASSEMBLY 147 SPECIAL TOOLS 149 T1 149 T2 149...

Page 6: ...6 Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 7: ...es Before going on to disassemble the parts and drain the oil it is best to thoroughly clean the unit removing any en crusted or accumulated grease INTRODUCTORY REMARKS All the disassembled mechanical...

Page 8: ...8 Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 9: ...Corporation ASM 0025E 212 Axle Service Manual SPECIFICATIONS DEFINITION OF VIEWPOINTS DATA PLATE 1 Model number 2 Serial number 3 Lubricant MFG BY CLARK HURTH COMPONENTS S P A 38062 Arco Trento MADE...

Page 10: ...PSI UNIT OF WEIGHT UNITS OF TORQUE N daN kN kg lbs 1N 1 0 1 0 001 0 102 0 225 1daN 10 1 0 01 1 02 2 25 1kN 1000 100 1 102 225 1kg 9 81 0 981 0 00981 1 2 205 N m daN m kN m kg m lb in 1N m 1 0 1 0 001...

Page 11: ...1202 N m 1411 1559 N m 1539 1701 N m 1710 1890 N m 1838 2032 N m M30 x 3 5 mm 1378 1523 N m 1473 1628 N m 1914 2115 N m 2085 2305 N m 2280 2520 N m 2494 2757 N m SIZE OF BOLT TYPE OF BOLT 8 8 8 8 Loct...

Page 12: ...0 N m 740 N m FLAT COLLAR WHEEL NUTS WITH SEPARATE SPHERICAL LOCK WASHER M18X1 5 mm 270 N m 360 N m M20X1 5 mm 360 N m 450 N m M22X1 5 mm 460 N m 550 N m WHEEL NUTS WITH INTEGRATE SEAT CAPTIVE WASHER...

Page 13: ...MAINTENANCE 13 Dana Holding Corporation ASM 0025E 212 Axle Service Manual MAINTENANCE MAINTENANCE POINTS 1 Oil fill plug 2 Oil drain plug 3 Check level plug 3 1 3 4 4 2 2 1 2 3 4...

Page 14: ...85W90 API GL5 MIL 2105 B With additives for oil bath brakes for units presenting hypoid crown wheel and pinion and or self locking differential gear Planetary reduction Every 200 hours Oil change Diff...

Page 15: ...up to 0 2 mm LOCTITE 577 Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80 Before using it remove any lubricant with the specific activator After polymer...

Page 16: ...16 MAINTENANCE Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 17: ...taining in the country where the axles are being overhauled 9 Make sure that only weak solvents are used for cleaning purposes avoid using turpentine dilutants and toluol xylolbased or similar solvent...

Page 18: ...18 MAINTENANCE Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 19: ...19 Dana Holding Corporation ASM 0025E 212 Axle Service Manual CHECKING WEAR AND REPLACING THE BRAKING DISCS EXPLODED VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 MAXIMUM 10...

Page 20: ...he intermediate disks on both sides if necessary CAUTION 1 T1 S T1 CAUTION FIGURE 3 Remove the swinging support 2 on the side op posite the drive NOTE If the bushing 17 is worn and needs replacing wri...

Page 21: ...xtract the u joint 18 FIGURE 8 Remove the reversal springs 8 from the piston 9 NOTE If the springs 8 are weak or deformed they must be re placed 3 7 18 7 8 8 9 FIGURE 9 Remove the pin screws 10 guidin...

Page 22: ...curately check the positioning of the anti extrusion rings 13 and 14 FIGURE 12 Insert the stroke automatic regulation springs 15 place them in line with the piston 9 9 3 14 13 12 11 CAUTION 9 15 15 FI...

Page 23: ...nd fit them inthe arm following the correct sequence orient them sothat the oil circulation holes and the marks B are perfectly lined up 10 8 8 9 CAUTION B 7 B NOTE When installing the steel discs the...

Page 24: ...24 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 2313 32 32 32 32 10 4 5 25 45 110 160 25 1 4 3 45 8 1 P N 2305 200 90 20 50 120 0 1 840 930 120 0 1...

Page 25: ...25 Dana Holding Corporation ASM 0025E 212 Axle Service Manual COMPLETE STEERING CASE EXPLODED VIEW 2 4 6 8 10 1 3 5 9 9 12 1 3 10 1 4 15 1 6 1 7 18...

Page 26: ...m the articulation pin 19 4 FIGURE 2 Using two levers remove the top articulation pin 4 complete with front seal 9 and shims 3 Pay attention not to damage the surfaces FIGURE 3 Remove the bottom artic...

Page 27: ...the top articulation pin 4 Lu bricate and install the unit in the steering case Position the screws 8 and tighten with torque wrench 140N m Check the correct assembly side of the seal 3 1 CAUTION 4 3...

Page 28: ...k with a lever that there is no vertical gap In case there is any gap determine the width and reduce it by removing shims FIGURE 12 Check the torque of the pins which has to be between 30 and 60 N m I...

Page 29: ...29 Dana Holding Corporation ASM 0025E 212 Axle Service Manual DOUBLE U JOINT EXPLODED VIEW 1 2 3 4 10 13 14 9 3 2 11 12...

Page 30: ...or the extraction of the double U joint use a plastic mallet or a lever FIGURE 3 Remove the snap ring 9 from the bushing unit 13 3 2 4 13 9 FIGURE 4 Position the entire u joint 4 under a press and re...

Page 31: ...1 FIGURE 8 Heat the bearing in oil at an approximate tempe rature of 100 C and fit the entire bushing 13 on the u joint 4 T5 T6 T1 T2 12 13 11 13 11 10 13 4 FIGURE 9 Fit the check ring 9 on the bushin...

Page 32: ...32 ASSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual FIGURE 12 Install the nuts 3 on the studs 2 and tighten them using a torque wrench Torque wrench setting 122 N m 3...

Page 33: ...ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3342 0 8 0 8 0 8 0 8 0 8 R5 0 0 1 54 79 0 15 90 7 x15 3 0 0 2 2 5 14 10 70 46 30 54 5 0 0 1 P N 2301 0 8 0 8 30 49 5 89 10 130 155 Proteggere...

Page 34: ...34 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 35: ...35 Dana Holding Corporation ASM 0025E 212 Axle Service Manual PLANETARY REDUCTION GEAR EXPLODED VIEW 3 16 17 18 19 1 2 4 5 6 8 9 10 11 12 13 20 9 10 7 14 15...

Page 36: ...ver 2 FIGURE 2 Disjoint the planetary carrier cover 2 from the steering case 3 by alternatively forcing a screwdriver into the appropriate slots FIGURE 3 Remove the complete planetary carrier cover 2...

Page 37: ...uller remove the complete crown flange 5 by acting on the stud bolts FIGURE 9 Remove the snap ring 12 from the crown 13 6 5 13 12 FIGURE 10 Remove the crown flange 5 FIGURE 11 Partially extract the hu...

Page 38: ...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...

Page 39: ...DISASSEMBLY 39 Dana Holding Corporation ASM 0025E 212 Axle Service Manual FIGURE 18 Remove the pins and remove the steering case 3 For details see COMPLETE STEERING CASE p 25 3...

Page 40: ...nstall the articulation pins For pin assembly details see COMPLETE STEERING CASE p 25 T7 T1 18 3 T8 T2 16 17 19 3 FIGURE 22 Position the lower part of tool T3A See drawing T3 p 45 and the thrust block...

Page 41: ...ng 14 Position the sealing ring 14 in the hub 7 NOTE Check that the ring 14 is correctly oriented FIGURE 27 Position tool T4 See drawing T4 p 46 and press the sealing ring 14 into its seat 15 14 7 T10...

Page 42: ...NOTE In order to fasten the flange 5 use a plastic hammer and alternately hammer on several equidistant points 12 13 5 5 FIGURE 33 Apply Tecnolube Seal 101 grease to the surface of the safety flange...

Page 43: ...37 Lock the gears 10 into position by fitting the snap rings 9 FIGURE 38 Fit the planetary carrier cover 2 onto the hub 3 Check that the o ring 20 is in good condition and in posi tion T11 T5 10 2 10...

Page 44: ...e Manual SPECIAL TOOLS T1 T2 P N 2303 0 8 0 8 35 0 1 0 2 50 25 64 50 x15 3 0 0 2 3 13 50 150 213 52 x15 5 R1 5 R 1 0 Proteggere da cementazione x45 2 P N 3363 0 8 0 8 0 8 35 0 1 0 2 50 56 64 x15 5 70...

Page 45: ...S 45 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 P N 3354 0 8 0 8 R 3 158 5 50 H7 30 20 140 150 200 0 03 100 0 3 0 5 132 16 113 148 158 5 35 129 117 102 20 40 0 08 0 12 50 R 3 95 25...

Page 46: ...Dana Holding Corporation ASM 0025E 212 Axle Service Manual T4 T5 P N 3502 0 8 0 8 0 8 0 8 120 40 41 19 5 5 0 2 0 3 1 0 0 1 139 5 153 168 180 x45 1 26 x15 5 x45 2 P N 2304 0 8 0 8 175 25 10 15 39 50 x1...

Page 47: ...47 Dana Holding Corporation ASM 0025E 212 Axle Service Manual STEERING CYLINDER EXPLODED VIEW 1 2 4 5 6 7 8 9 10 12 13 14 15 15 6 13 12 7 4 14 11 6 3 OLD 6 NEW...

Page 48: ...48 OPTICAL SENSOR AND MAGNETIC SENSOR Dana Holding Corporation ASM 0025E 212 Axle Service Manual OPTICAL SENSOR AND MAGNETIC SENSOR Optical sensor Magnetic sensor...

Page 49: ...Remove the castellated nuts 6 that lock the articulation pins 4 Dispose of used cotter pins FIGURE 3 NEW VERSION Remove the nuts 6 that lock the articulation pins 4 1 2 5 6 4 3 CAUTION 4 FIGURE 4 Dis...

Page 50: ...g 1 from the cylinder head 2 9 8 9 2 1 FIGURE 10 With the help of a plastic hammer push the head 2 inside the cylinder 3 NOTE The head should line up with the edge of the cylinder FIGURE 11 With the h...

Page 51: ...ssembly 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 NOTE...

Page 52: ...in the head 2 Thoroughly check that positioning of the anti extrusion 7 ring is correct 7 8 6 8 7 6 CAUTION 7 8 6 8 7 6 CAUTION FIGURE 17 Fit the seal 9 onto the outside of the head 2 1 In order to f...

Page 53: ...ammer FIGURE 21 Remove tool T1 See drawing T1 p 58 and ap ply it to the opposite side of the piston 5 5 3 T1 5 3 5 3 5 3 2 5 T1 5 2 FIGURE 22 Apply grease to head 2 seals fit the head onto the piston...

Page 54: ...ethod the screws 8 Torque wrench setting 116 128 N m 1 2 2 1 CAUTION 9 8 9 FIGURE 28 Apply Loctite 242 to the thread and connect the steering bars by screwing the terminals onto the piston stem Torque...

Page 55: ...ntering if applicable and tighten the screws 10 Torque wrench setting 5 6 N m 3 6 A 7 A CAUTION 1 Eliminate the action of the negative brake if fitted FIGURE 33 Apply tools T2 See drawing T2 p 59 to t...

Page 56: ...he centering of the piston must be carried out on the basis of the maximum stroke 1 2 3 4 I max 0 80 A NERO BLACK BLU BLUE MARRONE BROWN 2 A CONNETTORE CONNECTOR BATTERIA BATTERY C C C FIGURE 39 Witho...

Page 57: ...btained Check that articulations move easily and lock the collars 12 Torque wrench setting for nuts 42 52 N m FIGURE 43 CONVERGENCY ADJUSTMENT ON ALTERNA TIVE VERSIONS Loosen the nuts 11 and screw the...

Page 58: ...58 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2724 0 8 0 05 0 10 45 x1 25 M8 5 30 44 14 15 75 7 6 1 30 x45 1 6 5 0 0 05 20 4 0 05 0 43 6 R2 5...

Page 59: ...SPECIAL TOOLS 59 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 P N 1867 125 125 x45 5 17 0 1 50 100 R 1 1 0 R 1 5 27 5 0 2 55 500 555 23...

Page 60: ...60 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 61: ...61 Dana Holding Corporation ASM 0025E 212 Axle Service Manual DIFFERENTIAL UNIT EXPLODED VIEW 1 2 3 5 6 7 1 3 4...

Page 62: ...ing nuts 1 FIGURE 3 Uniformly heat the ring nuts 1 up to a tempera ture of 80 C 3 1 1 FIGURE 4 Apply tool T1 See drawing T1 p 66 and remove the ring nuts NOTE Accurately clean the threaded portions on...

Page 63: ...IGURE 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 N...

Page 64: ...discharge in the lo wer position 5 2 6 5 1 FIGURE 11 Lock the middle cover 5 with screws 4 Torque wrench setting for screw 23 8 26 2 N m FIGURE 12 Tighten ring nuts on the crown side until clearan ce...

Page 65: ...just the backlash between the pinion and the crown by loosening one of the ring nuts 1 and tightening the opposite to compensate Normal backlash see table A A A A T13 T1 FIGURE 17 Difference between M...

Page 66: ...vice Manual SPECIAL TOOLS T1 T2 P N 3333 0 8 0 8 125 35 5 x15 2 100 20 17 24 8 14 15H7 n6 238 33 10 x15 10 25 35 123 36 47 R 1 0 37H7 n6 106 0 1 R30 25 125 0 1 0 2 P N 3317 4 0 8 0 08 0 12 55 75 14 30...

Page 67: ...67 Dana Holding Corporation ASM 0025E 212 Axle Service Manual BEVEL PINION EXPLODED VIEW 1 2 3 5 6 7 10 4 11 13 12 8 9 14...

Page 68: ...T p 61 FIGURE 2 If disassembly is awkward heat the check nut 1 of the flange 2 at 80 C NOTE Heating is meant to loosen the setting of Loctite on the nut 1 2 1 FIGURE 3 Position tool T1A See drawing T1...

Page 69: ...f disassembly proves awkward heat the ring nut to ap proximately 80 C FIGURE 8 Apply blocks T4 See drawing T4 p 79 and with the help of a puller extract the pinion 8 complete with the in ternal bearin...

Page 70: ...SSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual 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 1...

Page 71: ...rust block in the center and take several measu rements while rotating the thrust block T24 DG T5 DG 9 CAUTION FIGURE 15 Partially insert the thrust block of the external be aring 13 FIGURE 16 Install...

Page 72: ...urement A at about 57 mm corresponding to the maximum diameter of arms centering T26B T26C T24 T7B T7C T5 13 T26A DG 1 GB GB T7A T26C T26A A A T7C T7A FIGURE 21 Calculate size B which will be the firs...

Page 73: ...and then remove the tools NOTE Before going on to the next stage make sure that the thrust block has been completely inserted B C S 14 9 14 T25C T25A T6C T6A FIGURE 27 Position tools T7C See drawing T...

Page 74: ...e the preload for the bearings FIGURE 32 Position the internal bearing 9 and the pinion 8 under a press force the bearing onto the pinion DDG T26C T26B H T7B T7C H 9 13 H 0 12 0 13 S1 11 S1 8 9 FIGURE...

Page 75: ...alue 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 stage...

Page 76: ...r in mind that a variation of shim 11 of 0 01 mm corresponds to a variation of 60 N cm in the torque of the pinion 8 FIGURE 42 Install the swinging support 5 NOTE Check that it is properly oriented T1...

Page 77: ...77 Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2308 80 0 2 105 120 15 0 2 105 25 25 10 50 0 2 185 0 0 2 34 5 125 125 61 5 100 15 10 45 126 150 12 61 5 73 97 85 135...

Page 78: ...S Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 T3 P N 3317 3 0 8 0 8 3 4 15H7 n6 0 08 0 12 55 75 35 x15 5 60 15 14 34 Tornito 32 25 P N 3317 A 0 8 85 55H7 7 60 66 22 75 10 6 20 40 20...

Page 79: ...SPECIAL TOOLS 79 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T4 T5 P N 2309 131 99 5 25 20 17 P N 2310 0 001 30 2 5X45 42 0 005 88 8...

Page 80: ...Manual T6 P N 3329 3 0 8 0 8 0 8 T25C T25B 35 0 08 0 12 19 5 433 5 473 5 5 45 11 5x15 0 1 0 2 16 5 M18x1 5 30 M18x1 5 40 15 23 3x15 55 83 56 66 10 0 1 0 20 R 2 R 2 0 08 0 12 89 19 55H7 23 40 73 40 88...

Page 81: ...OLS 81 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T7 P N 2312 0 0 03 41 2 20 x1 M14 25 50 25 95 50 10 195 110 x1 M14 65 20 41 0 01 0 02 61 30 R 5 40 15 300 14 x45 4 20 9 80 35 11 6 5 T...

Page 82: ...ation ASM 0025E 212 Axle Service Manual T8 T9 P N 3354 0 8 0 08 0 12 55 75 14 30 59 20 44 40H7 n6 M6 5 48 15 60 35 5x15 10 R5 1 4 Tornito 32 25 P N 3327 0 8 0 8 0 8 50 5x45 0 0 2 12 3x15 12 63 87 2 0...

Page 83: ...83 Dana Holding Corporation ASM 0025E 212 Axle Service Manual MANUAL EMERGENCY RELASE EXPLODED VIEW...

Page 84: ...e FIGURE 1 Loosen nuts 30 of screws 31 provided for the mechanical and manual release of the braking units then move the nuts backwards by approximately 8 mm FIGURE 2 Tighten screws 31 so as to fasten...

Page 85: ...no Lube 101 grease to the screws and install all parts into the arm FIGURE 5 Adjust screws 31 to obtain a distance of 34 0 5 mm between axle machined surface and screw underhead FIGURE 6 Lock into pos...

Page 86: ...86 ADJUST Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 87: ...87 Dana Holding Corporation ASM 0025E 212 Axle Service Manual MECHANICAL PARKING BRAKE EXPLODED VIEW 1 2 3 4 5 6 7 8 9 10 11 13 14 4 11 12 16 15...

Page 88: ...nyway FIGURE 1 Disconnect the steering bars from the steering ca se For details see STEERING CYLINDER p 47 FIGURE 2 Draw out the screw 1 locking the washer 2 that stops the lever 3 DANGER 1 2 3 FIGURE...

Page 89: ...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 FIGURE 8 If th...

Page 90: ...G DISCS p 19 12 13 14 11 10 9 10 FIGURE 12 Install the arms 8 into the main body check flat ness and block arms following the appropriate procedures il lustrated in section MECHANICAL PARKING BRAKE p...

Page 91: ...orce towards the braking direction in order to eli minate the idle stroke While the force is being applied tighten stud 16 until it is caused to rest onto bushing 6 FIGURE 17 Lock stud 16 in this posi...

Page 92: ...92 ASSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 93: ...93 Dana Holding Corporation ASM 0025E 212 Axle Service Manual EXTERNAL HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW 1 2 3 4 5 9 12 10 11 17 18 19 6 7 8...

Page 94: ...er to release the brakes NOTE If the machine hydraulic system cannot be used use an external manual pump FIGURE 2 Loosen and remove the external nut 7 DANGER 7 4 7 FIGURE 3 Release the pressure in the...

Page 95: ...e wrench setting of 20 25 N m Clearances should be set to zero without causing any pre loading 1 2 8 5 8 10 N 0 8 1kg 19 18 17 CAUTION FIGURE 9 Install cylinder 4 complete with rod 5 and inter nal nut...

Page 96: ...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...

Page 97: ...97 Dana Holding Corporation ASM 0025E 212 Axle Service Manual EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE EXPLODED VIEW 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 14 9 26 27 7 28 19 20 21 22...

Page 98: ...hat came with the vehi cle FIGURE 1 Before starting any operation on the assembly di sable the cylinder by giving a light hammer blow to the exter nal ring of the check unit FIGURE 2 Remove snap ring...

Page 99: ...x100 screw A into the hole of the check unit 7 and screw a nut B until the spring seat 11 is moved to the end of stroke NOTE Use a hex bolt FIGURE 8 Rotate snap ring 12 until ring ends match slot C Re...

Page 100: ...fety snap ring 5 onto the stem 6 In case the braking disks have been replaced or if brake pi stons have been removed before adjusting the negative braking unit apply the brakes several times at maximu...

Page 101: ...ing against the adjustment stud and cylinder 18 If necessary remove the lever turn it by one tooth in relation to the spline and repeat idle stroke elimination procedure 2 1 10 3 6 A 28 27 18 FIGURE 1...

Page 102: ...ASM 0025E 212 Axle Service Manual 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...

Page 103: ...103 Dana Holding Corporation ASM 0025E 212 Axle Service Manual INCOMING DRUM BRAKE EXPLODED VIEW 1 3 4 5 6 7 8 9 10 11 12 13 17 15 14 16...

Page 104: ...and remove dust from friction surfaces Use only brush type vacuum cleaners FIGURE 2 Hold the upper shoe into position 2 and release the spring 3 DANGER 1 CAUTION 3 2 FIGURE 3 Remove the shoe assembly...

Page 105: ...ge 10 and stop ring 7 FIGURE 7 Remove the seal 12 and discard it NOTE Write down assembly direction FIGURE 8 Remove the securing screws 13 from brake sup port 14 9 10 11 12 12 14 13 FIGURE 9 Remove br...

Page 106: ...Torque wrench setting 34 2 37 8 N m 16 15 14 13 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 NOTE Carefully check assemb...

Page 107: ...t in its seat FIGURE 18 If the lever 6 has been removed install it and hold it in position with the snap ring 5 Fit the shoes assembly 4 FIGURE 19 Make sure that the shoes 4 center the slot of the ful...

Page 108: ...LS Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2308 80 0 2 105 120 15 0 2 105 25 25 10 50 0 2 185 0 0 2 34 5 125 125 61 5 100 15 10 45 126 150 12 61 5 73 97 85 135...

Page 109: ...SPECIAL TOOLS 109 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 P N 3327 0 8 0 8 0 8 50 5x45 0 0 2 12 3x15 12 63 87 2 0 08 0 12 37 75 0 2 0 3 55 89 99 R5 74...

Page 110: ...110 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 111: ...rvice Manual 4 INCOMING BRAKE 2 AND 3 FUNCTION VERSIONS EXPLODED VIEW RKZA 0040 1 2 23 24 25 26 27 28 29 30 31 32 33 26 26 25 25 41 34 35 36 37 42 39 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 38...

Page 112: ...Remove nut 3 o ring 4 and flange 5 DANGER 1 2 3 4 5 3 4 5 NOTE If disassembly is awkward heat nut 3 about 176 F 80C FIGURE 4 Loosen screws 6 in an alternate and criss cross method until the action of...

Page 113: ...of a lever pry off the cover 23 com plete with o ring 24 CAUTION 17 17 18 18 19 23 24 NOTE Thoroughly clean the face of bevel pinion support where the hub rests check the o ring 24 and replace it if n...

Page 114: ...ONLY Slowly introduce compressed air through the connection point of the service brake to extract the piston 33 31 32 33 33 Hold piston 33 as it may be rapidly ejected and damaged FIGURE 15 2 FUNCTION...

Page 115: ...led for other rea sons than this If thickness A of one of the discs 26 is close to the mini mum admissible size of 1 36 mm replace the whole pack 33 34 35 36 37 34 36 37 35 A A min 1 36 mm 25 26 FIGUR...

Page 116: ...16 onto the piston 12 of the negative brake NOTE Carefully check the assembly position of the anti extru sion rings 34 33 35 36 37 35 34 36 37 12 13 14 15 16 13 14 15 16 FIGURE 25 Lubricate sealing r...

Page 117: ...ush it to end of stroke with a plastic hammer Check that the adjusting stakes 30 are thoroughly inserted and make sure they perform a sliding motion in relation to each other S 9 10 30 33 CAUTION FIGU...

Page 118: ...starts and ends with steel discs 25 FIGURE 35 Apply Loctite 510 on the face of the cover 23 Fit the discs hub cover assembly prepared in the previous stages onto the pinion and engage it 12 18 27 23 2...

Page 119: ...calculations and the separating ring 10 of the Belleville washers Fit shims and ring on the cover 8 NOTE Position the larger shim so that it leans against the cover FIGURE 41 Check the state of the o...

Page 120: ...nd negative brakes to an external pump introduce pressure up to a value of 20 25 N m 2 NOTE Check that pressure is kept stable for at least 5 minutes and make sure there are no leaks FIGURE 48 3 FUNCT...

Page 121: ...torque setting FIGURE 51 To release the negative brake during an emer gency lack of pressure due to vehicle breakdown loosen nuts 22 and screw studs 21 in an alternate and gradual manner until you no...

Page 122: ...ation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3739 0 8 0 8 0 8 50 3x15 3x45 5x45 R 5 64 84 5 94 5 110 0 2 0 110 120 140 5 15 3 0 5 15 65 P N 3317 3 0 8 0 8 3 4 15H7 n6 0 08 0 12 55 7...

Page 123: ...SPECIAL TOOLS 123 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 P N 3317 A 0 8 85 55H7 7 60 66 22 75 10 0 2 0 4 0 2 6 6 60 100 275 15...

Page 124: ...124 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 125: ...125 Dana Holding Corporation ASM 0025E 212 Axle Service Manual NORMAL DIFFERENTIAL UNIT EXPLODED VIEW 3 4 1 2 5 6 12 11 9 7 8 10 5 9 8 10 11 9 9 7 8 10 11 11 10 8 13...

Page 126: ...g 3 and remove the crown 2 FIGURE 3 Remove the shim washer 5 and the planetary gear 6 11 12 1 2 12 7 2 3 14 13 5 6 FIGURE 4 If the bearing need replacing extract the bearing 4 from the differential ca...

Page 127: ...T3 p 132 and guide bushing T2 See drawing T2 p 131 NOTE In this condition the tool T1 See drawing T1 p 131 con tains pin 9 15 17 12 9 CAUTION T16B T15 T16B T2 T3B T3B 12 9 T16A T15 T2 T3A FIGURE 10 Re...

Page 128: ...g T3 p 132 position the second planetary gear 7 and the relative shim washer 8 13 14 15 6 5 6 12 T16C T3C 7 8 T16A T16C T3A T3C 12 7 8 FIGURE 16 Insert tool T1 See drawing T1 p 131 between the two pla...

Page 129: ...B T16B T2 T3B T3B 9 9 T16B T15 T16B T1 T3B T3B 12 9 FIGURE 22 Remove press tool T3B See drawing T3 p 132 bushing T2 See drawing T2 p 131 and fit the snap ring 11 on the pin 9 Make sure that the snap r...

Page 130: ...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 FIGURE 2...

Page 131: ...ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3708 0 8 0 8 0 8 0 8 x45 1 41 25 20 0 2 0 26 18 36 5 20 5 5 R 1 M26X1 5 9 6 33 25 41 20 0 2 0 6 5 5 22 5 10 5 x45 1 31 P N 3424 0 8 0 8 30 0 1...

Page 132: ...on ASM 0025E 212 Axle Service Manual T3 T4 P N 2306 5 8 2 46 45 10 56 6 x30 3 9 9 1 0 3 2x30 10 29 6 6 19 6 x45 0 5 x30 1 175 9 9 1 9 9 1 T3A T3C T3B 0 1 0 0 2 0 5 0 1 0 1 0 0 1 0 P N 3332 0 8 0 8 0 8...

Page 133: ...on ASM 0025E 212 Axle Service Manual LIMITED SLIP DIFFERENTIAL UNIT 25 AND 45 EXPLODED VIEW 1 2 3 4 5 6 8 9 10 11 12 15 18 19 18 11 19 10 10 19 14 17 7 13 11 18 10 19 11 18 12 16 16 14 17 13 15 7 13 1...

Page 134: ...wn 4 NOTE Write down the position of the notches of the central hole in relation to the protrusions of the friction unit steel di scs FIGURE 3 If bearing 5 needs replacing remove it remove crown 4 1 2...

Page 135: ...wing T2 p 140 and insert press tool T3A See drawing T3 p 141 Press press tool T3A See drawing T3 p 141 to end of stroke T14 T1 12 12 9 11 CAUTION T16A T15 T16A T3A T3A T2 FIGURE 10 Remove press tool T...

Page 136: ...n ASM 0025E 212 Axle Service Manual 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 wh...

Page 137: ...17 As to rings 13 and 16 the side without notches must face outwards 9 7 6 18 2 0 1 6 6 16 17 15 14 13 CAUTION FIGURE 16 45 FRICTION UNIT COMPOSITION Friction ring with inner disc 13 intermediate disc...

Page 138: ...ind the planetary gears 12 After locking the tool remove bar T3C See drawing T3 p 141 FIGURE 21 Fit snap rings 19 onto the pins 11 T16C T14 T1 T3C T14 T1 6 6 11 19 FIGURE 22 Position the differential...

Page 139: ...e second friction disc assembly 7 into the differential unit 9 10 11 CAUTION 6 7 9 FIGURE 27 Line the lubrication holes up with the slots in the differential carrier Orient the holes of the crown 4 to...

Page 140: ...ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3708 0 8 0 8 0 8 0 8 x45 1 41 25 20 0 2 0 26 18 36 5 20 5 5 R 1 M26X1 5 9 6 33 25 41 20 0 2 0 6 5 5 22 5 10 5 x45 1 31 P N 3424 0 8 0 8 30 0 1...

Page 141: ...on ASM 0025E 212 Axle Service Manual T3 T4 P N 2306 5 8 2 46 45 10 56 6 x30 3 9 9 1 0 3 2x30 10 29 6 6 19 6 x45 0 5 x30 1 175 9 9 1 9 9 1 T3A T3C T3B 0 1 0 0 2 0 5 0 1 0 1 0 0 1 0 P N 3332 0 8 0 8 0 8...

Page 142: ...142 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 143: ...143 Dana Holding Corporation ASM 0025E 212 Axle Service Manual HYDRAULIC DIFFERENTIAL LOCK EXPLODED VIEW 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...

Page 144: ...ve the top cap 1 NOTE The cap must be replaced each time the unit is disassembled FIGURE 3 Remove the security switch 2 NOTE Check the state of the o ring 3 1 2 FIGURE 4 Loosen the lock nut 4 of selec...

Page 145: ...5 from piston 6 While hol ding the selector up remove the differential unit 15 FIGURE 9 Extract selector fork 5 14 13 5 15 5 FIGURE 10 Remove snap ring 12 and whole piston 6 FIGURE 11 Remove guide ri...

Page 146: ...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...

Page 147: ...Install bearing 16 onto the differential carrier 17 NOTE Make sure that the bearing is well set in the differential carrier 15 21 20 19 18 16 17 FIGURE 18 Fit o ring 10 and guide ring 11 onto the pis...

Page 148: ...n the coupling 19 and on the pi ston 6 T30 T2 6 12 5 15 22 FIGURE 24 Install the intermediate cover 13 and lock it with screws 14 Tighten screws using a torque wrench setting of 23 8 26 2 N m NOTE Car...

Page 149: ...Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3543 33 26 0 08 0 12 28 0 08 0 12 24 10 30 50 3x15 5 15 Proteggere da cementazione 0 8 0 8 P N 2316 18 M12x1 25 17 35 0 2...

Page 150: ...150 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 151: ...151 Dana Holding Corporation ASM 0025E 212 Axle Service Manual HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW 1 3 28 6 2 4 5 27 23 22 25 26 7 8 11 10 19 18 12 13 9 14 15 16 21 20 17 24 27 x x...

Page 152: ...f the ne gative brake and introduce a pressure of 15 30 bar to elimi nate the pressure of the Belleville washers 2 FIGURE 2 Sling the arm to be removed and connect it to a hoist Loosen and remove scre...

Page 153: ...them FIGURE 8 Loosen the studs and remove two of them 11 FIGURE 9 Move the cover 7 outwards FIGURE 10 Remove the Belleville washers 2 and write down direction of assembly FIGURE 11 Slowly introduce l...

Page 154: ...e compressed air through the connection member for the negative brake in or der to extract the piston 3 Hold the piston 3 back as it may be suddenly ejected and damaged 3 CAUTION FIGURE 14 Remove brak...

Page 155: ...er all around the edge in an alternate se quence FIGURE 18 Fit o rings 9 and 8 onto the piston 10 Lubricate the piston and the o rings and install the unit into the cylinder 7 3 7 3 7 10 7 FIGURE 19 U...

Page 156: ...tive centering FIGURE 22 Check quality and position of the cylinder s o ring FIGURE 23 Position the Belleville washers 2 and engage the cylinder 7 NOTE Check the sense of direction of washers 2 and re...

Page 157: ...tic regulation springs 19 place them in line with the piston 11 FIGURE 29 Insert the intermediate disk 11 11 19 11 FIGURE 30 Fit the reversal springs 12 13 on the piston 11 FIGURE 31 Apply LOCTITE 270...

Page 158: ...7 N m FIGURE 34 Take the measurement from the surface of the intermediate disk to the cover sealing surface with 30 bar of pressure introduced EXAMPLE 25 4 mm FIGURE 35 Put the brake disc pack includi...

Page 159: ...l circulation holes and the marks B are lined up When installing the steel discs the slot corresponding to the oil level cap should always be kept free FIGURE 39 Check integrity and position of the ar...

Page 160: ...160 ASSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual...

Page 161: ...161 Dana Holding Corporation ASM 0025E 212 Axle Service Manual INCORPORATED REDUCTION GEAR AND PINION 602 EXPLODED VIEW 1 2 3 4 7 8 9 10 12 13 14 15 16 19 21 22 25 3 4 5 6 10 14 11 17 18 20 23 24 21...

Page 162: ...gear with Mechanic flanges disassembly and as sembly procedures also apply to DIN flanges FIGURE 2 Loosen the check nuts on upper 1 and lower 2 flange FIGURE 3 Draw out nuts 3 and o rings 4 1 2 2 3 4...

Page 163: ...and tapping lightly with a hammer separate the cover 9 from the body of the reduction gear 11 FIGURE 9 Insert two levers in the provided slots and move the cover 9 away from the body of the reduction...

Page 164: ...GURE 15 Remove inner bearing 14 from gear assembly 12 12 14 15 9 12 12 14 14 FIGURE 16 Remove outer bearing 14 and spacer 16 FIGURE 17 Disjoin from the steering case the steering bar lo cated by the s...

Page 165: ...FIGURE 21 Remove ring nut 19 19 T29 T30 T1 T2 19 FIGURE 22 Using a puller extract pinion 20 complete with inner bearing 21 spacer 22 and distance washers NOTE The thrust blocks of the bearings remain...

Page 166: ...oriented NOTE Apply grease to the outer surface of the spacer 22 T7 T3 11 22 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 i...

Page 167: ...EPLACING THE BRAKING DISCS p 19 Also connect the steering bar FIGURE 31 Using a press fit the bearings 14 and the spa cer 16 on the upper gear 12 The di stance piece 16 must be positioned between the...

Page 168: ...36 Block cover 9 with screws 7 and 8 and rela tive washers 10 Tighten using the criss cross method Torque wrench setting 82 91 N m FIGURE 37 Fit the upper 1 and lower 2 flanges Apply Loctite 242 to th...

Page 169: ...SPECIAL TOOLS 169 Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 0 8 0 8 3 4 15H7 n6 0 08 0 12 55 75 35 x15 5 60 15 14 34 32 25...

Page 170: ...170 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 0 8 85 55H7 7 60 66 22 75 10 6 20 40 20 6 60 100 275 15...

Page 171: ...SPECIAL TOOLS 171 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 0 8 0 8 35 0 1 0 2 50 25 64 50 x15 3 0 0 2 3 13 50 150 213 52 x15 5 R 1 5 R 1 0 x45 2...

Page 172: ...olding Corporation ASM 0025E 212 Axle Service Manual T4 T4C T4B T4A 64 40H8 54 70 M18X1 5 50 267 312 5x15 M18X1 5 40H8 30 17min R3 R3 23 3x15 40 55 83 0 08 0 12 89 56 10 66 2 1 R2 R 2 R2 1 5 0 0 2 19...

Page 173: ...SPECIAL TOOLS 173 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T5 0 8 0 8 2x15 2x45 5x45 R5 55 60 0 2 0 3 72 0 2 0 3 30 30 130 1 10 12 152...

Page 174: ...SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual T6 80 0 2 105 120 15 0 2 105 25 25 10 50 0 2 185 0 0 2 34 5 125 125 61 5 100 15 10 45 126 150 12 61 5 73 97 85 135 0 5 32 T6A...

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Page 176: ...ne service parts ordering visit www SpicerParts com order asp Copyright 2013 Dana Holding Corporation All content is subject to copyright by Dana and may not be reproduced in whole or in part by any m...

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