Repair Manual
MAN-00
190
THAR
CRDe
BS-IV
MAY
2012
/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
Symptoms
Causes
Remedial Action
Oil Leakage
Make sure that a suspected oil
leak is actually coming from the
hub. Oil leaks can originate in
the axle shaft (oil seal).
• A cracked or porous or
improper fitment of protective
end cap.
• Damaged or missing "O" rings.
•
Incorrectly installed or
damaged sealing ring of the End
Cap and outer clutch housing.
Replace the end cap.
Fit a new ‘O’ ring.
Fit properly.
Does not engage/ disengage
Before disassembly of a locking
hub, be sure the problem is
caused by the hub and not
another component in the drive
train.
• Transfer case not engaging or
disengaging front axle shaft.
• Viscosity of fron
t differential
lubricant too high (i.e. due to
cold weather).
• Front differential preload too
high.
• Seized front axle shaft
bearing.
Replace the end cap.
Check & fill proper lubricant.
Rectify.
Rectify / Replace.
Noisy Operation
A broken or missing 4 tanged washer can cause problems in 2 or 4 ‐ wheel drive.
A broken or missing washer will allow the drag sleeve to rotate with the brake band. If the hub is not
engaged, the brake band is unable to lock on the drag sleeve and initiate the locking action of the
clutches. If the hubs are engaged, the brake band cannot be released to allow the clutch gear to
disengage.
A broken or missing brake band cannot lock the inner cage to engage the hub or be unlocked by the
outer sleeve to allow the clutch gear to disengage.
If both brake band tangs are touching the centre post of the outer sleeve, there cannot be proper
locking or unlocking action of the brake band through the movement of the inner cage and outer cage.
The centre post of the outer cage and the window of the inner cage move relative to each other when
the hub is locking or unlocking. If the cages are not rotating freely over each other, the hub may fail to
engage or disengage.
A sticking clutch gear can cause the hub to bind in either the engage or the disengage position. A
broken return spring will cause the hub to remain in the engaged position.
In each case, the defective component should be replaced with the correct part or assembly. Always
check the most recent parts list for the correct part numbers and available assemblies for the type of
the hub you are servicing.
Lubrication
• Remove drag sleeve assembly and keep aside DO NOT lubricate drag sleeve assembly as it is
permanently lubricated with Darmex grease.
• Check the brake b
and and drag sleeve serration for presence of appropriate quantity of grease and
wear, in case of insufficient grease, replace the drag sleeve.
• DO NOT remove the brake band as this could change the spring tension and affect hub operation.
• All components except drag sleeve assembly and outer bearing race assembly are lubricated by
dipping them in automatic transmission fluid. Allow excess fluid to drip off before assembling the hub.
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