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ZF AV 133, Repair Instructions


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45. Evenly support the portal housing on the

hydraulic press from below at the edges (1).

46. Place the bush (2) with the groove showing

downwards onto the portal housing.

47.

Risk of crushing due to hydraulic tool.

Slight to moderate injury possible.

ð

Do not reach into danger area.

Press the bush (2) with max. 60 kN by using

AA02.041.051 [Driver tool] (3) and

5870.700.004 [Load cell] (4) into the

housing.

Fig. 223  

48. Insert retaining ring.

Fig. 224  

49. Press bearing outer rings onto the output

gear.

Fig. 225  

Assembly

112

EN 4472.751.001 - 2015-11

Summary of Contents for AV 133

Page 1: ...REPAIR INSTRUCTIONS AV 133 Bus axle with compact bearing BUSES...

Page 2: ...cted by copyright Complete or partial reproduction or distribution of this document is not permitted without the approval of ZF Friedrichshafen AG Infringements lead to civil and criminal prosecution...

Page 3: ...rques 15 7 Workshop Equipment 17 7 1 Special tools 17 7 2 Standard tools and fixtures 30 7 3 Operating supplies and auxiliary materials 35 8 Dismantling 36 8 1 Clamp the axle 36 8 2 Drain oil 36 8 3 R...

Page 4: ...tal drive 103 9 6 1 Assemble right portal drive 103 9 6 2 Install right portal drive 116 9 7 Install breather neck 117 9 8 Install breather 118 9 9 Install tachometer 118 9 10 Assemble and install hub...

Page 5: ...by authorized trained and instructed specialized staff only It is the responsibility of the company that performs repair assembly or maintenance tasks to ensure that their specialized staff is proper...

Page 6: ...provisions Work must only be performed by trained instructed and authorized specialized staff Only original ZF spare parts may be used Only original ZF accessories may be used Only original ZF specia...

Page 7: ...uspended loads Keep distance Lifting and moving heavy parts without tools may lead to health damage or serious injury Only use permitted means of transport lifting tools with a sufficient load capacit...

Page 8: ...ing supplies and auxiliary materials in a sufficiently large container Dispose of operating supplies and auxiliary materials waste containers soaked cleaning cloths contaminated filters etc in accorda...

Page 9: ...to a severe injury or death Information as to how the danger can be prevented CAUTION The signal word CAUTION indicates a dangerous situation that if not prevented can lead to a slight or moderate in...

Page 10: ...ust ensure that the ZF product is again functioning perfectly and is safe to operate 3 2 Cleaning the ZF product Clean the ZF product with an appropriate cleaning agent prior to repair or assembly wor...

Page 11: ...sable parts Remove sealing compound residue on sealing faces or retaining agent residue e g in tapped holes or on splines Clean joining surfaces Clean blind holes and blind hole threads Lubricating bo...

Page 12: ...impaired Minor damage includes Indentation marks on sealing faces Score marks or burs caused by the disassembly of the ZF product Frictional corrosion Damage caused by paint or corrosion If rework is...

Page 13: ...pe plate contains the most important data TE ML TE ML TE ML ltr List of lubricants Customer s Code No Oil Parts List No Total Ratio Version Made in Germany Serial No ZF Friedrichshafen AG Type 3 1 2 4...

Page 14: ...axle ratio i 7 38 Total rolling torque Pinion bearing rollin g torque 2 Nm 1 Nm Torque wrench with dial gauge Setting backlash and differential bearing rolling torque and checking axial run out and c...

Page 15: ...her page 118 Stud bolt 33 Nm Torque wrench Assemble left portal drive page 88 Cylindrical screw 185 Nm Torque wrench Assemble left portal drive page 88 Assemble right portal drive page 103 Hexagon nut...

Page 16: ...suring instrument Comment Chapter section Screw plug oil filling M24 x 1 5 70 Nm Torque wrench Filling oil page 131 Screw plug oil level M24 x 1 5 70 Nm Torque wrench Filling oil page 131 Tightening T...

Page 17: ...le page 36 1 5870 350 000 Assembly truck Clamp the axle page 36 Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88 Assemble right portal driv...

Page 18: ...e 42 Dismantling hub page 44 1 1 set 2 units 5870 401 146 Slotted nut wrench Remove hub page 42 Install hub page 124 1 AA01 395 095 Load carrying fixture Remove hub page 42 Install hub page 124 1 5870...

Page 19: ...ive page 102 Install right portal drive page 116 2 M20 x 1 5 5870 350 110 Connection plate Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assemble left portal drive page 88...

Page 20: ...2 length of sleeve 125 mm AA02 049 488 Disassembly device Dismantling left portal drive page 48 1 5870 281 054 Eye nut Dismantling left portal drive page 48 Dismantle right portal drive page 58 Assem...

Page 21: ...id grip Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 5870 300 035 Extracting device Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 5870 20...

Page 22: ...58 mm 5870 300 003 Extracting device Dismantling left portal drive page 48 Dismantle right portal drive page 58 1 AA01 305 639 removing tool Dismantling left portal drive page 48 1 14 mm AA02 038 564...

Page 23: ...e drive page 86 1 AA00 640 418 Support fixture Remove input page 70 Install input page 74 Install shaft seal onto the drive page 86 1 5870 203 002 Power screwdriver Remove input page 70 Install input...

Page 24: ...r Remove input page 70 2 5870 080 044 Press out device Remove input page 70 1 5873 002 051 Gripping device Remove input page 70 1 M95 x 2 5870 300 020 Extracting device Remove input page 70 1 5870 345...

Page 25: ...page 88 Assemble right portal drive page 103 1 Length 160 mm 5870 056 008 Driver tool Install input page 74 1 5870 204 025 Locating pin Assemble differential page 79 1 1 set 2 units M14 x 1 5 x 85 AA...

Page 26: ...checking axial run out and contact pattern page 81 1 Length 390 mm AA01 266 870 Load lifting equipment Setting backlash and differential bearing rolling torque and checking axial run out and contact p...

Page 27: ...le right portal drive page 103 1 5870 058 061 Driver tool Assemble left portal drive page 88 Assemble right portal drive page 103 1 5870 200 094 Measuring arbor Assemble left portal drive page 88 Asse...

Page 28: ...o Assemble left portal drive page 88 Assemble right portal drive page 103 Install tachometer page 118 1 5870 610 010 Assembly fixture Assembling hub page 120 1 Use only in connection with insert 5870...

Page 29: ...e 120 1 Length 230 mm 5870 345 121 Support arbor Assembling hub page 120 1 AA00 607 922 Driver tool Assembling hub page 120 1 5870 651 085 Assembly aid Install hub page 124 1 5870 204 029 Locating pin...

Page 30: ...870 203 030 Torque wrench 0 6 Nm to 6 0 Nm 5870 203 031 Torque wrench 1 0 Nm to 12 Nm 5870 203 032 Torque wrench 3 0 Nm to 23 Nm 5870 203 033 Torque wrench 5 0 Nm to 45 Nm 5870 203 034 Torque wrench 1...

Page 31: ...00 mm 5870 970 002 Two armed extractor Jaw width 120 mm Throat depth 125 mm 5870 970 003 Two armed extractor Jaw width 170 mm Throat depth 125 mm 5870 970 004 Two armed extractor Jaw width 200 mm Thro...

Page 32: ...idth 295 mm Throat depth 235 mm 5870 971 005 Three armed extractor Jaw width 390 mm Throat depth 270 mm 5870 971 006 Three armed extractor Jaw width 640 mm Throat depth 300 mm Fig 9 5870 281 026 Lifti...

Page 33: ...g 13 5870 345 071 Pry bar Fig 14 5870 280 004 Plastic hammer 5870 280 006 Nylon insert Spare part Fig 15 5870 650 004 Striker Fig 16 5870 200 055 Magnetic holder Fig 17 5870 200 057 Dial gauge Worksho...

Page 34: ...Load bearing capacity min 1 500 kg Arbor press Manual operation Press force max 30 kN Hydraulic press Hydraulic actuation Tab 3 Other Equipment Comment Requirement Socket wrenches open end wrenches bo...

Page 35: ...l shaft seal onto the drive page 86 0666 690 078 Sealing compound Loctite 243 Threadlockers Assemble left portal drive page 88 Install mounting parts page 129 0666 790 037 Sealing compound Drei Bond S...

Page 36: ...ture 5870 350 000 Assembly truck 1 Fix axle 1 with 5870 350 093 Fixture 2 to 5870 350 000 Assembly truck 3 Support axle from below 4 Fig 21 8 2 Drain oil Observe the environmental regulations see Gene...

Page 37: ...l drain screw plugs 2 2 Remove screw plug oil filling 3 In case of the version with mounted breather slight overpressure can build up in the axle 3 Remove screw plug oil level 1 and O ring 4 Remove sc...

Page 38: ...the upper longitudinal control arm 2 Fig 23 2 Loosen hexagon screws 1 and remove the lower longitudinal control arm 2 Fig 24 3 Loosen hexagon nut 4 and remove disk 3 joint ring 2 and disk 1 4 Remove...

Page 39: ...er 1 by means of lifting device 8 Loosen hexagon screws and remove spring carrier Fig 27 8 4 Removal of brake Special tools 5870 281 046 Load carrying fixture 5870 204 084 Eyebolt Observe the specific...

Page 40: ...Tightening torque 20 Nm 5 Nm maximum loosening torque Fig 28 2 Loosen locknuts 3 Remove brake cylinder Fig 29 4 Remove rubber cap 5 Turn adjuster in counterclockwise direction manually until contact i...

Page 41: ...cket 3 Fig 31 9 Remove brake lining set Fig 32 10 Fix brake caliper with 5870 281 046 Load carrying fixture 1 5870 204 084 Eyebolt 2 and crane 11 Loosen hexagon screws and fit bolt on the brake calipe...

Page 42: ...s 5870 345 036 Pry bar 5870 401 146 Slotted nut wrench AA01 395 095 Load carrying fixture 1 Fix hub Loosen bolted connection of the flange shaft Fig 34 2 Pull out flange shaft with 5870 345 036 Pry ba...

Page 43: ...d nut with 5870 401 146 Slotted nut wrench 6 Remove retaining plate Fig 37 7 Use AA01 395 095 Load carrying fixture to fix the hub to the crane 8 Loosen slotted nut with 5870 401 146 Slotted nut wrenc...

Page 44: ...8 5 2 Dismantling hub Special tools 5870 345 036 Pry bar 5870 100 069 Assembly fixture 1 Risk of crushing due to hydraulic tool Slight to moderate injury possible Do not reach into danger area Use pre...

Page 45: ...1 5 Use 5870 345 036 Pry bar to pull ABS ring out of the hub and remove it Fig 42 6 Remove retaining ring 1 7 Remove tapered roller bearing at the brake disk side from the hub Fig 43 Dismantling EN 44...

Page 46: ...g Fig 44 9 Press tapered roller bearing and shaft seal from the hub Fig 45 10 Risk of injury due to parts flying away Slight or moderate injury possible Wear protective goggles Force out bearing outer...

Page 47: ...Remove tachometer 1 Pull cable 1 out of the clamp 2 2 Remove clamp Fig 47 3 Push tachometer out of the hub carrier Fig 48 4 Push bush out of the hub carrier Fig 49 Dismantling EN 4472 751 001 2015 11...

Page 48: ...erate injury possible Secure parts against falling down Remove portal with differential and stub shaft Stub shaft can also be removed from the right side 3 Pull stub shaft out of the differential 4 Pu...

Page 49: ...ice 5873 012 013 Rapid grip 5870 300 035 Extracting device 5870 204 022 Locating pin 5870 300 007 Extracting device 5870 300 003 Extracting device AA01 305 639 removing tool 1 Fix portal drive with 58...

Page 50: ...p and 5873 002 001 Basic tool 6 Remove shim Fig 55 7 Slide AA02 049 488 Disassembly device onto the drive gear stub shaft 8 Tighten cylindrical screws of AA02 049 488 Disassembly device evenly Tighten...

Page 51: ...10 Remove parts from the drive gear Fig 57 11 Loosen Torx screws and remove hub carrier with 5870 281 054 Eye nut Fig 58 12 Remove O ring 1 Fig 59 Dismantling EN 4472 751 001 2015 11 51...

Page 52: ...Extracting device to pull the bearing inner ring out of the hub carrier Fig 60 14 Use a three armed puller to pull the screen sheet from the hub carrier Fig 61 15 Remove the output gear from the porta...

Page 53: ...rip to pull both tapered roller bearings from the output gear Fig 63 17 Pull bearing outer ring 1 with 5870 300 035 Extracting device out of the portal housing 18 Remove shim Fig 64 19 Loosen cylindri...

Page 54: ...Force out and remove bearing bolt Fig 66 22 Remove O rings 1 Fig 67 23 Hold shaft washer axial roller cage and disk 1 24 Push tapered roller bearing 2 and intermediate gear outwards and remove the rel...

Page 55: ...ight or moderate injury possible Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 70 27 Loosen cylindrical screw on the bearing bolt 28 Bolt in 5870 204 022 Locating...

Page 56: ...oller bearing and intermediate gear Fig 73 32 Risk of injury due to parts flying away Slight or moderate injury possible Wear protective goggles Force bearing inner rings out of the intermediate gear...

Page 57: ...st washers out of the portal housing Fig 75 34 Use AA01 305 639 removing tool to loosen the stud bolts Fig 76 8 8 Remove breather 1 Open hose clamp 1 2 Pull corrugated hose and hose 2 from the breathe...

Page 58: ...e injury possible Secure parts against falling down Remove portal and stub shaft Stub shaft can also be removed from the left side 3 Pull stub shaft from the portal 4 Remove two pieces AA00 844 345 Lo...

Page 59: ...ip 5870 300 035 Extracting device 5870 204 022 Locating pin 5870 300 007 Extracting device 5870 300 003 Extracting device 1 Fix portal drive with 5870 350 110 Connection plate to 5870 350 000 Assembly...

Page 60: ...ng ring Fig 82 4 Insert three piece tool of AA02 038 564 Disassembly device into the bush Fig 83 5 Push bush of AA02 038 564 Disassembly device onto the three piece tool Fig 84 Dismantling 60 EN 4472...

Page 61: ...into the three piece tool 7 Hold spindle of AA02 038 564 Disassembly device Turn hexagon nut and pull bush out of the portal housing Fig 85 8 Remove drive gear and individual parts Fig 86 9 Remove re...

Page 62: ...ith 5870 281 054 Eye nut Fig 88 11 Remove O ring 1 Fig 89 12 Use 5870 300 009 Extracting device and 5870 300 019 Extracting device to pull the bearing inner ring out of the hub carrier 13 Remove shim...

Page 63: ...et from the hub carrier Fig 91 15 Remove the output gear from the portal housing Fig 92 16 Use 5873 002 001 Basic tool and 5873 012 013 Rapid grip to pull both tapered roller bearings from the output...

Page 64: ...70 300 035 Extracting device out of the portal housing Fig 94 18 Loosen cylindrical screw Fig 95 19 Bolt in 5870 204 022 Locating pin at the bearing bolt 20 Force out and remove bearing bolt Fig 96 Di...

Page 65: ...washer axial roller cage and disk 2 23 Push tapered roller bearing 1 and intermediate gear outwards and remove the releasing parts 2 Fig 98 24 Remove tapered roller bearing and intermediate gear Fig 9...

Page 66: ...ssible Wear protective goggles Force bearing inner rings out of the intermediate gear Fig 100 26 Loosen cylindrical screw Fig 101 27 Bolt in 5870 204 022 Locating pin at the bearing bolt 28 Force out...

Page 67: ...oller bearing and intermediate gear Fig 104 31 Risk of injury due to parts flying away Slight or moderate injury possible Wear protective goggles Force bearing inner rings out of the intermediate gear...

Page 68: ...106 8 10 Dismantle differential Special tools 5873 002 025 Gripping device 5873 002 001 Basic tool 5870 300 009 Extracting device 5870 300 019 Extracting device AA02 015 365 Fixing spider 1 Use 5873 0...

Page 69: ...xtracting device and AA02 015 365 Fixing spider to pull the bearing outer ring out of the differential Fig 108 3 Fix differential Loosen locking screws Fig 109 4 Press differential out of the crown wh...

Page 70: ...er 5870 240 002 Locking mechanism 5870 400 001 Offset screwdriver 5870 080 044 Press out device 5873 002 051 Gripping device 5873 002 001 Basic tool 5870 300 019 Extracting device 5870 300 020 Extract...

Page 71: ...e input flange with a three armed puller from the pinion Fig 113 3 Press screen sheet from the input flange Fig 114 4 Use 5870 400 001 Offset screwdriver to remove the shaft seal from the axle housing...

Page 72: ...ess the pinion out of the tapered roller bearing and remove it Fig 116 6 Remove ring Fig 117 7 Use 5873 002 051 Gripping device and 5873 002 001 Basic tool to pull off the tapered roller bearing Fig 1...

Page 73: ...g 119 9 Use a suitable plate and 5870 080 044 Press out device to press the bearing outer ring out of the housing 10 Remove shim Fig 120 11 Risk of injury due to parts flying away Slight or moderate i...

Page 74: ...Support fixture 5870 203 002 Power screwdriver 1 Read dimension U 1 from the axle housing Dimension U e g 201 20 mm Fig 122 2 Compare mating number 1 e g 17 with mating number on the crown wheel Both...

Page 75: ...Calculation example s U A B C s 201 20 mm 0 05 mm 150 mm 50 05 mm s 1 1 mm Fig 125 8 Carry out the following two work steps immediately one after the other Risk of burn injuries due to contact with c...

Page 76: ...derate injury possible Wear protective gloves Undercool the bearing outer ring 1 12 Insert bearing outer ring 1 into axle housing until contact is obtained Fig 127 13 Use 5870 345 080 Assembly fixture...

Page 77: ...tapered roller bearing 17 Insert pinion into the axle housing from inside Slide the heated tapered roller bearing onto the pinion until contact is obtained Fig 131 18 If available insert the hexagon...

Page 78: ...sassembly Tightening torque 1 000 Nm Fig 134 23 Rotate pinion several times in both directions 24 Check the necessary pinion bearing rolling torque 4 Nm 10 Nm 25 If the rolling torque is too small ret...

Page 79: ...n wheel Both mating numbers must be identical 2 Note ideal backlash 1 e g 0 22 mm Fig 136 3 Bolt in two pieces 5870 204 025 Locating pin into the crown wheel 4 Risk of burn injuries due to contact wit...

Page 80: ...ten crosswise Tightening torque 250 Nm Fig 138 7 Insert bearing outer ring with AA02 015 690 Driver tool and 5870 260 002 Handle until contact is obtained Fig 139 8 Press in bearing inner ring with AA...

Page 81: ...im with s e g 1 mm into the axle housing 2 Use 5870 058 070 Driver tool and 5870 260 003 Handle to insert the bearing outer ring Fig 141 3 Cover several drive and coast flanks on the crown wheel with...

Page 82: ...m 9 Turn pinion Speed 50 1 min Duration always left and right 15 s Fig 144 10 Place dial gauge at right angled surface of a hexagon screw at the differential 11 Backlash bevel gear set e g 0 22 mm 0 0...

Page 83: ...he front face of the AA02 060 628 Test device to the front face of the bearing inner ring Measure distance of each hole and calculate average Distance A e g 59 44 mm Fig 147 15 Remove AA02 060 628 Tes...

Page 84: ...nting face of the portal housing to the contact face of the bearing inner ring Distance C e g 26 26 mm 21 Calculate shim thickness for Differential bearing rolling torque 4 Nm 7 Nm Calculation example...

Page 85: ...eral times into both directions 31 Check total rolling torque Total rolling torque at axle ratio i 7 38 Total rolling torque Pinion bearing rolling torque 2 Nm 1 Nm Total rolling torque at axle ratio...

Page 86: ...er tool Operating supplies and auxiliary materials 0666 690 191 Spirit 0666 690 313 Sealing compound 1 Use AA02 016 086 Plug insert AA00 640 418 Support fixture and 5870 203 002 Power screwdriver to l...

Page 87: ...313 Sealing compound onto the thread Use AA02 016 086 Plug insert AA00 640 418 Support fixture and 5870 203 002 Power screwdriver to tighten the double hexagon nut Tightening torque 1 000 Nm Fig 155...

Page 88: ...le 5870 058 061 Driver tool 5870 200 094 Measuring arbor 5870 204 022 Locating pin AA02 041 051 Driver tool 5870 700 004 Load cell AA00 372 127 Driver tool 5870 281 054 Eye nut AA00 387 830 Pressing f...

Page 89: ...housing Tightening torque 33 Nm Fig 158 4 Use AA02 041 179 Driver tool and 5870 260 002 Handle to insert the bushes thrust washers into the portal housing Fig 159 5 In case of used bearings always al...

Page 90: ...2 Handle to insert the bearing inner rings into the intermediate gear Fig 161 7 Put the intermediate gear onto the tapered roller bearing Fig 162 8 Slide the tapered roller bearing onto the bearing bo...

Page 91: ...r with a pry bar and check the necessary setting of the intermediate gear bearing 0 01 mm preload 0 05 mm clearance If the required axial play is not reached replace the shim as specified below In cas...

Page 92: ...nto the intermediate gear 18 Place intermediate gear and tapered roller bearing onto a bush thrust washer in the portal housing Fig 167 19 Grease O rings 1 and insert them into the annular grooves 20...

Page 93: ...Locating pin Fig 169 24 Fix bearing bolt with a cylindrical screw Tightening torque 185 Nm Fig 170 25 Set the bearing of the second intermediate gear as illustrated 26 Insert the tapered roller bearin...

Page 94: ...to wrong arrangement of the parts possible Observe installation position of the individual parts Put the roller cage onto the shaft washer Radius or chamfer on the internal diameter of the shaft wash...

Page 95: ...ousing 1 and hold them 34 Place tapered roller bearing and intermediate gear 2 in such a way that the stacked parts are fixed in the hole 1 Fig 176 35 Grease O rings 1 and insert them into the annular...

Page 96: ...178 40 Fix bearing bolt with a cylindrical screw Tightening torque 185 Nm Fig 179 41 Place shaft washer 4 onto the drive gear 42 Place the axial roller cage 3 onto the drive gear 43 Place disk 2 onto...

Page 97: ...at the edges 1 47 Place the bush 2 with the groove showing downwards onto the portal housing 48 Risk of crushing due to hydraulic tool Slight to moderate injury possible Do not reach into danger area...

Page 98: ...he lower bearing outer ring and onto the upper bearing outer ring 53 Measure total height of output gear tapered roller bearing and rings Total height A e g 165 05 mm Fig 185 54 Measure height of the...

Page 99: ...44 68 mm 58 Calculate thickness s of the shim Calculation example s Housing depth D Dimension F Total height output gear and tapered roller bearing C s 180 83 mm 44 68 mm 135 05 mm s 1 1 mm Fig 188 5...

Page 100: ...0 260 002 Handle to insert the bearing outer ring Fig 190 62 Place the output gear into the portal housing Fig 191 63 Grease the O ring and insert it into the annular groove on the hub carrier 1 Fig 1...

Page 101: ...m Fig 194 66 Put the screen sheet onto the hub carrier 67 Align the recess of the screen sheet on the boss of the hub carrier 68 Align the recess of the AA00 387 830 Pressing fixture no on the boss of...

Page 102: ...moderate injury possible Move load slowly and carefully Do not reach into danger area Slide differential onto the drive gear 2 Apply 0666 790 037 Sealing compound 1 onto the portal housing 3 Grease O...

Page 103: ...drive 9 6 1 Assemble right portal drive Special tools 5870 350 110 Connection plate 5870 350 000 Assembly truck AA02 041 179 Driver tool 5870 260 002 Handle 5870 058 061 Driver tool 5870 700 004 Load...

Page 104: ...s thrust washers into the portal housing Fig 200 3 Slide the tapered roller bearing onto the bearing bolt Fig 201 4 Use 5870 058 061 Driver tool and 5870 260 002 Handle to insert the bearing inner rin...

Page 105: ...mediate gear onto the tapered roller bearing Fig 203 6 Slide the tapered roller bearing onto the bearing bolt Fig 204 7 Put shim with e g s 2 80 mm onto the bearing bolt Fig 205 Assembly EN 4472 751 0...

Page 106: ...bearing 0 01 mm preload 0 05 mm clearance If the required axial play is not reached replace the shim as specified below In case of an insufficient axial play install a thicker shim In case of an exces...

Page 107: ...17 Grease O rings 1 and insert them into the annular grooves 18 Glue the determined shim 2 with grease onto the bearing bolt 19 Bolt 5870 204 022 Locating pin 3 into the bearing bolt Fig 209 20 Slide...

Page 108: ...ted 24 Insert the tapered roller bearing into the portal housing 25 Insert the intermediate gear into the portal housing Fig 212 26 Insert the tapered roller bearing into the intermediate gear 27 Plac...

Page 109: ...haft washer Radius or chamfer on the internal diameter of the shaft washer must be opposite of the roller cage Fig 214 29 Place disk with radius or chamfer on the outer diameter showing upwards onto t...

Page 110: ...n the 2 hole are fixed Fig 217 33 Grease O rings 1 and insert them into the annular grooves 34 Glue the determined shim 2 with grease onto the bearing bolt 35 Bolt 5870 204 022 Locating pin 3 into the...

Page 111: ...gear Thereby the retaining ring in the drive gear must show downwards 41 Place the axial roller cage 3 onto the drive gear 42 Place disk 2 onto the drive gear 43 Place cup spring 1 with the concave si...

Page 112: ...ing 47 Risk of crushing due to hydraulic tool Slight to moderate injury possible Do not reach into danger area Press the bush 2 with max 60 kN by using AA02 041 051 Driver tool 3 and 5870 700 004 Load...

Page 113: ...e total height of output gear tapered roller bearing and rings Total height A e g 165 05 mm Fig 226 53 Measure height of the rings Total height of the rings B e g 30 00 mm 54 Calculate total height of...

Page 114: ...F Total height output gear and tapered roller bearing C s 180 83 mm 44 68 mm 135 05 mm s 1 1 mm Fig 229 58 Insert the determined shim 59 Use AA00 372 127 Driver tool and 5870 260 002 Handle to insert...

Page 115: ...ortal housing Fig 232 62 Grease the O ring and insert it into the annular groove on the hub carrier 1 Fig 233 63 Place hub carrier with 5870 281 054 Eye nut and crane onto the portal housing Fig 234 A...

Page 116: ...e screen sheet on the boss of the hub carrier 67 Align the recess of the AA00 387 830 Pressing fixture no on the boss of the hub carrier 68 Use AA00 387 830 Pressing fixture no to force the screen she...

Page 117: ...ing and bring the portal housing into contact position with the axle housing Fig 237 5 Support axle from below 1 6 Fix portal drive with Torx screws Tightening torque 185 Nm Fig 238 9 7 Install breath...

Page 118: ...mp 1 onto the hose 3 Push the hose 2 onto the breather neck 4 Secure hose 2 with hose clamp 1 Fig 240 9 9 Install tachometer Special tools AA00 387 830 Pressing fixture no Operating supplies and auxil...

Page 119: ...act face of the compact bearing Fig 242 4 Align the recess of the AA00 387 830 Pressing fixture no on the boss of the hub carrier Push AA00 387 830 Pressing fixture no slowly until contact position wi...

Page 120: ...ort arbor AA00 607 922 Driver tool 1 Use the tools only with hubs where wheel studs have already been installed Use 5870 610 010 Assembly fixture and 5870 610 002 Insert to install the wheel studs Fig...

Page 121: ...nner ring and bearing cage 40_020226_01 1 2 3 4 Fig 247 1 Grease 2 O ring 3 Retaining ring 4 Compact bearing consisting of two individual tapered roller bearings 4 Place bearing inner ring at the brak...

Page 122: ...nner ring into the hub Fig 249 8 Press the outer bearing inner ring slowly downwards until engagement of the retaining ring is audible 9 Rotate hub several times in both directions Fig 250 10 Check wh...

Page 123: ...the shaft seal at the brake disk side Fig 253 13 Put hub onto the brake disk 14 Risk of crushing due to hydraulic tool Slight to moderate injury possible Do not reach into danger area Use press to fi...

Page 124: ...5 Assembly aid AA01 395 095 Load carrying fixture 5870 401 146 Slotted nut wrench 5870 204 029 Locating pin Operating supplies and auxiliary materials 0671 190 180 Grease 1 Push 5870 651 085 Assembly...

Page 125: ...h Tightening torque 100 Nm 7 Rotate hub several times in both directions 8 Tighten slotted nut with 5870 401 146 Slotted nut wrench Tightening torque 850 Nm 9 Mount locking plate with the tab showing...

Page 126: ...1 Fig 259 13 Grease O ring 1 and insert it into the annular groove on the flange shaft Fig 260 14 Bolt two pieces 5870 204 029 Locating pin into the hub 15 Push flange shaft into the hub carrier Fig...

Page 127: ...ebolt Observe the specifications of the brake manufacturer 1 Use 5870 281 046 Load carrying fixture 1 5870 204 084 Eyebolt 2 and crane to place the brake caliper onto the hub carrier brake carrier 2 S...

Page 128: ...pin 2 into the opposite driving direction into the hole on the brake caliper 7 Push disk 1 onto pin 2 8 Fix pin 2 with spring split pin Fig 265 9 Mount brake cylinder with the connections showing back...

Page 129: ...aling compound 1 Screw in two units 5870 204 044 Locating pin 2 Fix spring carrier 1 by means of lifting device 3 Push on spring carrier 1 and align in horizontal position 4 Manually bolt in two screw...

Page 130: ...hock absorber 5 to the spring carrier 12 Push disk 1 joint ring 2 and disk 3 at the thread of the shock absorber 13 Fix shock absorber with hexagon nut 4 Tightening torque 70 Nm Fig 270 14 Horizontall...

Page 131: ...the upper longitudinal control arm 2 with hexagon screws 1 Tightening torque 390 Nm Fig 272 9 13 Filling oil Observe the environmental regulations see General safety instructions Fig 273 1 Screw plug...

Page 132: ...nt from the currently valid ZF List of Lubricants Slowly fill in oil at the oil filling hole until the bottom edge of the oil level hole 1 is reached 4 Check oil level after some minutes and correct i...

Page 133: ...eel Fig 274 Ideal contact pattern Left Crown wheel convex drive side 1 Ideal contact pattern 3 Heel Right Crown wheel concave coast side 2 Toe The possible deviations and required correction measures...

Page 134: ...he root Fig 275 Tooth root contact Left Crown wheel convex drive side 1 Contact pattern too close to the root 3 Heel Right Crown wheel concave coast side 2 Toe 1 Insert a thinner pinion distance disk...

Page 135: ...s the tip Fig 276 Tooth tip contact Left Crown wheel convex drive side 1 Contact pattern too close at the tip 3 Heel Right Crown wheel concave coast side 2 Toe 1 Insert a thicker pinion distance disk...

Page 136: ...11 Annex 11 1 Overview of revisions Index Date of issue Initiator Chapter Section Comment 11 2015 First edition Tab 5 Annex 136 EN 4472 751 001 2015 11...

Page 137: ......

Page 138: ...EN 4472 751 001 2015 11 ZF Friedrichshafen AG ZF Services Donaustra e 71 94034 Passau Deutschland Germany Telefon Phone 49 851 494 0 Telefax Fax 49 851 494 905 000 www zf com...

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