JLG 3507 Supplemental Repair Manual Download

Page: 1 / 180

An Oshkosh Corporation Company

Drive Axle

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

Supplemental Repair Manual

Summary of Contents for 3507

Page 1: ...orporation Company Drive Axle 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 Supplemental Repair Manual ...

Page 2: ...urer 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 Contact the component manufacturer for the latest information ...

Page 3: ...Service Manual Axle 212 October 2013 ASM 0025E ...

Page 4: ......

Page 5: ...ATIONS 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...

Page 6: ...ED 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 HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE 97 EXPLODED VIEW 97 DISASSEMBLY 98 ASSEMBLY 100 INCOMING DRUM BRAKE 103 EXPLODED VIEW 103 DISASSEMBLY 104 ASSEMBLY 106 SPECIAL TOOLS 108 T1 108 T2 109 4 INCOMING ...

Page 7: ...PLODED 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 HYDRAULIC NEGATIVE BRAKE 151 EXPLODED VIEW 151 DISASSEMBLY 152 ASSEMBLY 155 INCORPORATED REDUCTION GEAR AND PINION 602 161 EXPLODED VIEW 161 DISASSEMBLY 162 ASSEMBLY 166 SPECIAL TOOLS 169 T1 169 T2 ...

Page 8: ...6 Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 9: ...hes 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 units should be thoroughly cleaned with appropriate products and restored or replaced if damage wear cracking or seizing have occurred In particular thoroughly check the condition of all moving part...

Page 10: ...8 Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 11: ...g 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 IN ITALY 3 2 1 ...

Page 12: ... 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 0 102 8 854 1daN m 10 1 0 01 1 02 88 54 1kN m 1000 100 1 102 8854 1kg m 9 81 0 981 0 00981 1 86 8 1 lb in 0 1129 0 01129 0 0001129 0 01152 1 ...

Page 13: ... 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 Loctite 270 10 9 10 9 Loctite 270 12 9 12 9 Loctite 270 M8 x 1 mm 25 7 28 3 N m 27 5 30 5 N m 36 2 39 8 N m 40 44 N m 42 8 47 2 N m 47 5 52 5 N m M10 x 1 25 mm 49 4 54 6 N m 55 2 61 N m 71 5 78 5 N m 78 ...

Page 14: ...30 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 M18X1 5 mm 260 N m 360 N m M20X1 5 mm 350 N m 500 N m M22X1 5 mm 450 N m 650 N m NOTE The wheel nut tightening torque is related only on nut thread and stud thread dry Without oil or any lubricant NO...

Page 15: ...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 16: ...E85W90 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 Differential Every 800 hrs Planetary reduction Every 1000 hrs L S Differential Every 700 hrs Adjustment Negative brake Every 1000 hrs Only for mineral oil use e g ATF Dexron II Make sure that master cyli...

Page 17: ... 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 polymerisation disassembly may result rather difficult so heating may be necessary for larger diameters LOCTITE 638 Anaerobic adhesive for fast and high strength gluing of cylindrical metal joints hub on sh...

Page 18: ...16 MAINTENANCE Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 19: ...btaining 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 solvents use light solvents such as Kerosene mineral spirits or water based environment friendly solvents 10 For the sake of clarity the parts that do not normally need to be removed have not been reproduce...

Page 20: ...18 MAINTENANCE Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 21: ...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 22: ...the 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 write down the assembly side of the connection notch A FIGURE 4 Disconnect the pins of the steering bars from the steering case See STEERING CYLINDER p 47 Sling the arm 3 to be removed and put the rod u...

Page 23: ...Extract 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 guiding the piston 9 If the screws are to be replaced write down the different co lors for the different brake gap FIGURE 10 Slowly introduce compressed air through the connection of the braking circuit in...

Page 24: ...ccurately 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 FIGURE 13 Lubricate the seals 11 and 12 and fit the piston 9 into the arm 3 Make sure that the piston seat fits into the stop pin A inside the arm FIGURE 14 Assist the insertion of the piston 9 by ligh...

Page 25: ...and 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 slot corresponding to the oil level cap should always be kept free FIGURE 18 Check that the positioning of the sealing ring 16 on the arm is intact install the complete arm Lock it into position usi...

Page 26: ...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 27: ...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 28: ...om 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 articulation 19 pin complete with front sealing ring 10 15 19 4 8 4 9 3 CAUTION 19 10 FIGURE 4 Remove the complete steering case 1 4 3 19 1 ...

Page 29: ...o 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 3 140 N m 3 4 FIGURE 8 Lubricate steering case FIGURE 9 Fit the unit 19 in the steering case 1 Position the screws 15 and tighten Check for the correct assembly side of the seal 10 FIGURE 10 Tighten t...

Page 30: ...ck 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 If the preliminary measured value is too high the shims have to be increased 30 60 N m ...

Page 31: ...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 32: ...for 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 move the complete bushing 13 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 NOTE Write the assembly side of the ring ...

Page 33: ...11 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 bushing unit 13 also put the o ring 14 into position FIGURE 10 Insert the u joint and tighten the top and bottom studs 2 Torque wrench setting maximum 15 N m NOTE For u joint coming with a bushing center t...

Page 34: ...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 35: ...M 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 Ø54 Ø79 0 15 Ø90 7 x15 3 0 0 2 2 5 14 10 70 46 Ø30 Ø54 5 0 0 1 P N 2301 0 8 0 8 Ø30 49 5 89 10 130 155 Proteggere da cementazione 30 R 1 x45 3 x45 1 5 R 1 0 ...

Page 36: ...34 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 37: ...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 38: ... 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 1 1 2 2 3 2 FIGURE 4 Remove the snap rings 9 FIGURE 5 With the help of a puller remove the planetary wheel gears 10 NOTE Write down the assembly side of planetary wheels FIGURE 6 Loosen and remove th...

Page 39: ...puller 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 hub 7 using a plastic ham mer NOTE Alternately hammer on several equidistant points FIGURE 12 Remove the external bearing 8 5 7 8 ...

Page 40: ...e 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 FIGURE 17 Use a puller to remove the centering ring 16 the sealing ring 17 and the bearing 18 from the steering case 3 NOTE Write down the orientation of both centering ring 16 and sealing rin...

Page 41: ...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 42: ...install 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 of the external bearing 8 under the press FIGURE 23 Lubricate the seats of the bearings and position the hub 7 on tool T3A See drawing T3 p 45 position the thrust block of the internal bearing 15 NO...

Page 43: ...ing 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 T4 14 FIGURE 28 Install the hub 7 FIGURE 29 Install the external bearing 8 NOTE Using a plastic hammer drive the bearing to the limit stop by lightly hammering around the edge FIGURE 30 Insert the f...

Page 44: ...5 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 6 which touches the crown flange 5 Fit the safety flange 6 FIGURE 34 Apply Loctite 242 to the studs and fit on the nuts 4 FIGURE 35 Tighten the nuts 4 using criss cross method in two stages Initial t...

Page 45: ...E 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 9 3 2 20 CAUTION FIGURE 39 Lock the planetary carrier cover 2 by tightening the screws 1 Torque wrench setting for screws 40 50 N m FIGURE 40 Connect the steering bars For details see COMPLETE STEER...

Page 46: ...nual SPECIAL TOOLS T1 T2 P N 2303 0 8 0 8 Ø35 0 1 0 2 Ø50 Ø25 Ø64 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 Ø35 0 1 0 2 Ø50 Ø56 Ø64 x15 5 70 13 150 233 0 0 2 3 75 50 Ø25 Ø75 x45 3 R10 Proteggere da cementazione ...

Page 47: ...Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 P N 3354 0 8 0 8 R 3 Ø158 5 Ø50 H7 Ø30 20 Ø140 Ø150 Ø200 0 03 100 0 3 0 5 Ø132 16 113 148 Ø158 5 Ø35 129 117 102 20 Ø40 0 08 0 12 Ø50 R 3 Ø95 25 R 3 R5 8x15 ...

Page 48: ...a Holding Corporation ASM 0025E 212 Axle Service Manual T4 T5 P N 3502 0 8 0 8 0 8 0 8 120 Ø40 41 19 5 5 0 2 0 3 1 0 0 1 Ø139 5 Ø153 Ø168 Ø180 x45 1 26 x15 5 x45 2 P N 2304 0 8 0 8 175 25 10 15 Ø39 Ø50 x15 2 x45 2 R 3 Ø35 ...

Page 49: ...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 50: ...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 51: ...5 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 Disconnect the tapered pins of the articulation 4 from the steering case 7 by means of a puller FIGURE 5 If the connection of the steering bars includes a safety collar 13 raise the border FIGURE 6 Disc...

Page 52: ...ng 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 help of a drift apply pressure to the stop ring 4 that is placed inside the cylinder 3 and extract the ring using a screwdriver FIGURE 12 Hammer the piston 5 on the rear of the head 2 using a plastic ...

Page 53: ...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 NOTE 1 All seals must be replaced every time the unit is disas sembled 2 Particular attention must be paid not to damage the seats of both seals and piston slide A 3 5 2 A CAUTION ...

Page 54: ...8 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 facilitate assembly apply grease to the outer surface of the piston 2 Do not roll the seal 9 up FIGURE 18 Prepare the piston 5 by fitting it with the guide ring 10 the magnetic ring 11 the o ring 12 a...

Page 55: ...hammer 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 and push it into the cylinder 3 using a plastic ham mer NOTE Insert the head as to line it up with the edge of the cylin der FIGURE 23 Insert the stop ring 4 ensuring that it fits into the seat of th...

Page 56: ...method 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 wrench setting 240 270 N m NOTE Versions with coupling require that the rim of the articu lation 13 is riveted onto the surfaces of the piston stem FIGURE 29 OLD VERSION Insert the pins 4 in the ste...

Page 57: ...entering 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 the hubs and lock them Using a level B check that tools are perfectly flat and paral lel to each other FIGURE 34 Connect the sensor 1 to the inspection device according to either diagram FIGURE 35 Sen...

Page 58: ...the 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 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 check that to...

Page 59: ...obtained 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 them onto the ball and so cket joints 15 12 16 15 11 FIGURE 44 Hold the articulations still and rotate the ball and socket joints 15 Once the convergency has been adjusted lock the nuts 11 Torque wrench...

Page 60: ...58 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2724 0 8 0 05 0 10 Ø45 x1 25 M8 5 30 44 14 15 75 7 6 1 30 x45 1 Ø6 5 0 0 05 Ø20 4 0 05 0 Ø43 6 R2 5 ...

Page 61: ...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 Ø23 ...

Page 62: ...60 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 63: ...61 Dana Holding Corporation ASM 0025E 212 Axle Service Manual DIFFERENTIAL UNIT EXPLODED VIEW 1 2 3 5 6 7 1 3 4 ...

Page 64: ...ring 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 ring nuts of body and cover FIGURE 5 Remove the capscrews 4 from the middle cover 5 FIGURE 6 Insert a screwdriver in the opposing slots then for ce and remove the middle cover 5 and the complete dif...

Page 65: ...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 6 5 2 10 7 ...

Page 66: ... 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 between pinion and crown is zero then lock the crown go back 1 4 1 2 turn NOTE If the ring nuts 1 are removed coat them with Loctite 242 FIGURE 13 Pre set the bearings by means of the ring nut si tua...

Page 67: ...djust 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 MIN and MAX clearance for whole circumference should not exceed 0 09 mm FIGURE 18 Apply Loctite 242 to the screws 3 fit them into one of the two holes and tighten Torque wrench setting 23 8 26 2 N m F...

Page 68: ...ual SPECIAL TOOLS T1 T2 P N 3333 0 8 0 8 Ø125 Ø35 5 x15 2 100 20 17 24 8 Ø14 Ø15H7 n6 238 33 Ø10 x15 10 Ø25 Ø35 123 36 Ø47 R 1 0 Ø37H7 n6 Ø106 0 1 R30 25 125 0 1 0 2 P N 3317 4 0 8 0 08 0 12 Ø55 Ø75 14 30 59 Ø20 Ø44 Ø40H7 n6 M6 5 48 15 60 35 5x15 Ø10 R5 1 4 Tornito Ø 32 25 ...

Page 69: ...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 70: ...IT 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 p 77 or T1B so as to avoid pinion rotation Loosen and remove the nut 1 also remove the o ring 3 FIGURE 4 Remove the flange 2 complete with guard 4 by means of a puller FIGURE 5 Remove the swinging s...

Page 71: ...If 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 bearing 9 the spacer 10 and shims 11 NOTE The thrust blocks of the bearings remain in the central body 12 6 T21 T22 T2 T3 7 T23 T4 8 12 FIGURE 9 Remove the pinion 8 shims 11 and spacer 10 FIGURE 10 Using a...

Page 72: ...ASSEMBLY 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 14 9 14 ...

Page 73: ...hrust 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 tension rod T6C See drawing T6 p 80 measurement ring T5 See drawing T5 p 79 and front guide tool T6A See drawing T6 p 80 on the thrust block of the ex ternal bearing 13 FIGURE 17 Connect the tension...

Page 74: ...surement 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 first useful value for calculating the size of the shims 14 that are to be inserted under the thrust block of the internal bearing 9 FIGURE 22 Check the nominal size X marked on the pinion and add or sub...

Page 75: ... 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 T7 p 81 and T7B See drawing T7 p 81 complete with tapered bearings 9 and 13 manually tighten until a rolling torque has been obtained FIGURE 28 Insert the stem of a depth gauge DDG in either side hole...

Page 76: ...ne 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 33 Fit the pinion 8 shim S1 11 and spacer 10 in the main body 12 NOTE The thinner shims must be placed in between the thicker ones FIGURE 34 Insert the external bearing 13 in the central body in ord...

Page 77: ...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 If torque does not reach the minimum value then the size of shim S1 11 needs to be reduced When calculating the increase or decrease in size of shim S1 bear in...

Page 78: ...ar 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 T19 T2 CAUTION 5 FIGURE 43 Fit the flange 2 complete with the guard 4 and fasten it For seating the flange 2 use a plastic hammer if necessary NOTE Make sure that the guard 4 is securely fastened onto ...

Page 79: ...Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2308 80 0 2 Ø105 120 15 0 2 Ø105 25 25 10 Ø50 0 2 Ø185 0 0 2 Ø34 5 125 125 61 5 100 15 10 Ø45 126 150 12 61 5 73 97 85 135 0 5 Ø32 T1A T1B ...

Page 80: ...ana Holding Corporation ASM 0025E 212 Axle Service Manual T2 T3 P N 3317 3 0 8 0 8 3 4 Ø15H7 n6 0 08 0 12 Ø55 Ø75 35 x15 5 60 15 14 34 Tornito Ø 32 25 P N 3317 A 0 8 Ø85 Ø55H7 7 60 Ø66 22 75 10 6 20 40 20 6 60 100 275 15 ...

Page 81: ...SPECIAL TOOLS 79 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T4 T5 P N 2309 131 99 5 25 20 Ø17 P N 2310 0 001 Ø30 2 5X45 Ø42 0 005 Ø88 8 ...

Page 82: ...al T6 P N 3329 3 0 8 0 8 0 8 T25C T25B Ø35 0 08 0 12 Ø19 5 433 5 473 5 5 45 11 5x15 0 1 0 2 Ø16 5 M18x1 5 30 M18x1 5 Ø40 15 23 3x15 Ø55 Ø83 56 66 10 0 1 0 Ø20 R 2 R 2 0 08 0 12 Ø89 Ø19 55H7 23 40 73 Ø40 Ø88 Ø83 21 R 2 R5 R 2 21 0 8 0 8 0 8 0 8 0 8 0 8 T6A T6A T6B T6c T6B T6C ...

Page 83: ...81 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T7 P N 2312 0 0 03 Ø41 2 Ø20 x1 M14 25 50 25 95 50 10 195 Ø110 x1 M14 Ø65 20 41 0 01 0 02 61 30 R 5 40 15 300 14 x45 4 Ø20 Ø9 Ø80 35 Ø11 Ø6 5 T7A T7B T7C ...

Page 84: ...ASM 0025E 212 Axle Service Manual T8 T9 P N 3354 0 8 0 08 0 12 Ø55 Ø75 14 30 59 Ø20 Ø44 Ø40H7 n6 M6 5 48 15 60 35 5x15 Ø10 R5 1 4 Tornito Ø 32 25 P N 3327 0 8 0 8 0 8 Ø50 5x45 0 0 2 12 3x15 12 63 87 2 0 08 0 12 Ø37 75 0 2 0 3 Ø55 Ø89 Ø99 R5 74 ...

Page 85: ...83 Dana Holding Corporation ASM 0025E 212 Axle Service Manual MANUAL EMERGENCY RELASE EXPLODED VIEW ...

Page 86: ...le 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 them onto the pressure plate 23 DANGER 29 30 31 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...

Page 87: ...cno 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 position with nuts 30 Hold screws 31 into position while locking the nuts 30 af ter locking check the distance of screws 31 once more Tecno Lube 101 34 mm 27 26 CAUTION ...

Page 88: ...86 ADJUST Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 89: ...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 90: ...anyway 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 3 Remove washer 2 lever 3 and o rings 4 Mark the positions of levers 3 in relation to the thrust levers 12 and 13 FIGURE 4 Draw out the screws 5 and remove bushing 6 along with o ring 7 FIGURE 5 Con...

Page 91: ...s 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 thrust levers 12 and 13 need replacing remo ve the U joint 14 before removing the arms 8 For details see DOUBLE U JOINT p 29 9 10 10 11 8 12 13 14 ...

Page 92: ...NG 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 87 and HYDRAULIC NEGATIVE BRAKE p 151 FIGURE 13 Install the bushing 6 complete with o ring 7 and block it with screws 5 Tighten screws with a torque wrench setting of 23 8 26 2 N m FIGURE 14 Install ...

Page 93: ...force 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 position with nut 15 Torque wrench setting 20 25 N m 3 16 15 8 10 N 0 8 1kg 6 3 16 3 16 15 The idle stroke should be eliminated without preloading thrust levers 12 and 13 FIGURE 18 After connecting the c...

Page 94: ...92 ASSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 95: ...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 96: ...der 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 cylinder and discon nect the pressure delivery tube Remove the fulcrum pin 3 from the cylinder 4 complete with washers 12 FIGURE 4 Remove the cylinder assembly 4 complete with rod 5 internal nut 6 a...

Page 97: ...ue 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 6 FIGURE 10 Center the hole of fulcrum pin 3 and washers 12 Apply Loctite 242 to the pin thread screw and tighten pin with a torque wrench set at 25 30 N m FIGURE 11 Introduce pressure into the cyli...

Page 98: ... 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 A 4 5 mm 5 4 18 19 13 ...

Page 99: ...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 100: ...that 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 1 and extract spacer 2 DANGER 2 1 FIGURE 3 Remove the fulcrum pin 3 from the cylinder 4 complete with washers 22 FIGURE 4 Remove the complete cylinder set 4 FIGURE 5 Remove snap ring 5 from stem 6 an...

Page 101: ...4x100 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 Remove snap ring 12 7 8 9 9 10 B A A B 7 11 C C 12 FIGURE 9 Slowly release nut B and disassemble the check unit FIGURE 10 Loosen nut 17 and remove stem 6 from the cylinder 18 B B 11 11 13 14 14 15 16 6...

Page 102: ...afety 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 maximum pressure in order to set clearances FIGURE 15 Loosen nuts 26 and apply a force of 8 10 N 0 8 1 kg to levers 28 Direct the force towards the braking direction to eliminate the clearances by using st...

Page 103: ...ting 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 19 Introduce pressure into the cylinder 4 and with the levers 28 resting against the adjustment studs 27 screw rod 6 to engage the quick release 7 in the slot FIGURE 20 Lock nut 17 in position against...

Page 104: ...n 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 is actually engaged onto the rod 6 7 ...

Page 105: ...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 106: ... 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 4 If necessary remove the snap ring 5 and pull out the lever 6 FIGURE 4 Remove the snap ring 7 from its seat around the screws 8 Remove the screws 8 FIGURE 5 Fit tool T1A See drawing T1 p 108 or T1B ...

Page 107: ...nge 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 brake support 14 FIGURE 10 Remove the spacer 15 NOTE If operations are to be carried out the bevel pinion see the specific axle section 14 16 15 ...

Page 108: ... 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 assembly direction FIGURE 15 Install parts in the following sequence flange 10 o ring 11 and nut 9 Spread Loctite 242 on the threaded portion of the pinion 16 FIGURE 16 Fit tools T1A See drawing T1 p 108 o...

Page 109: ...et 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 fulcrum pin and rest on the surface of the lever 6 7 8 4 5 6 2 3 FIGURE 20 Fit the drum 1 NOTE Make sure that the friction surface of the drum carries no trace of grease and is perfectly clean 1 ...

Page 110: ... Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 P N 2308 80 0 2 Ø105 120 15 0 2 Ø105 25 25 10 Ø50 0 2 Ø185 0 0 2 Ø34 5 125 125 61 5 100 15 10 Ø45 126 150 12 61 5 73 97 85 135 0 5 Ø32 T1A T1B ...

Page 111: ...SPECIAL TOOLS 109 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 P N 3327 0 8 0 8 0 8 Ø50 5x45 0 0 2 12 3x15 12 63 87 2 0 08 0 12 Ø37 75 0 2 0 3 Ø55 Ø89 Ø99 R5 74 ...

Page 112: ...110 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 113: ...ervice 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 40 6 19 FUNCTION VERSION 3 FUNCTION VERSION ONLY ...

Page 114: ... 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 Belleville washers 11 becomes null Remove screws 6 and spring washers 7 of cover 8 FIGURE 5 Pull out cover 8 shims 9 separating ring 10 and Belleville washers 11 NOTE Take note of the assembly direct...

Page 115: ... 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 ne cessary FIGURE 10 Remove friction discs 25 26 and hub 27 FIGURE 11 3 FUNCTION VERSION ONLY Loosen nuts 28 and unscrew studs 29 to retract the adjustment points 30 ONLY IF NECESSARY Remove points 30...

Page 116: ... 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 VERSION ONLY Remove the spacer 39 FIGURE 16 Remove sealing ring 38 from cover 8 NOTE Take note of direction of assembly of ring 38 and replace ring every time the unit is disassembled FIGURE 17 Remo...

Page 117: ...bled 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 FIGURE 20 BRAKING DISCS PACK CONTENTS The braking discs pack is comprised of 11 braking discs and 12 steel counterdiscs FIGURE 21 If the braking discs unit is replaced shims 9 which determine the preloadi...

Page 118: ...4 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 ring 38 and using tool T1 See drawing T1 p 122 fit it into the cover 8 NOTE Carefully check the direction of ring 38 FIGURE 26 3 FUNCTION VERSION ONLY Measure size A1 of piston 12 and note it down FIG...

Page 119: ...push 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 FIGURE 30 3 FUNCTION VERSION ONLY Insert springs 32 for piston 33 backward movement FIGURE 31 3 FUNCTION VERSION ONLY Apply Loctite 242 to the thread of screws 31 and tighten NOTE Tighten the screws with...

Page 120: ... 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 25 26 23 FIGURE 36 Lubricate the o ring 24 and fit cylinder 18 complete with piston 12 FIGURE 37 Introduce screws 17 and tighten in a criss cross method Use a torque wrench setting of 9 5 10 5 N m NOT...

Page 121: ...o 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 ring 40 Lubricate sealing ring 38 and fit flange 5 into the cover 8 A B 10 8 9 10 5 8 38 40 FIGURE 42 Fit the Belleville washers 11 onto the cover 8 thoroughly checking washers orientation FIGURE 43...

Page 122: ...and 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 FUNCTION VERSION ONLY Screw studs 29 until pins 30 position themselves against the piston 33 then unscrew studs by one turn to obtain a 1 5 mm stroke Lock studs 29 into position with the nuts 28 tightened...

Page 123: ...d 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 notice some preloading continue by giving another 1 5 turns 0 8 1 2mm 1 CAUTION 21 22 FIGURE 52 When the emergency is over loosen the studs in an alternate manner until a 17 mm projection is obtained l...

Page 124: ...n ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3739 0 8 0 8 0 8 Ø50 3x15 3x45 5x45 R 5 Ø64 Ø84 5 Ø94 5 Ø110 0 2 0 110 120 140 5 15 3 0 5 15 65 P N 3317 3 0 8 0 8 3 4 Ø15H7 n6 0 08 0 12 Ø55 Ø75 35 x15 5 60 15 14 34 Tornito Ø 32 25 ...

Page 125: ...SPECIAL TOOLS 123 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 P N 3317 A 0 8 Ø85 Ø55H7 7 60 Ø66 22 75 10 0 2 0 4 0 2 6 6 60 100 275 15 ...

Page 126: ...124 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 127: ...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 128: ...ng 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 carrier 12 FIGURE 5 Remove the snap rings 11 from the two pins 9 of the planetary gears 7 FIGURE 6 Insert tool T1 See drawing T1 p 131 between the planetary gears 7 15 8 4 12 17 16 11 9 T14 T1 7 7 ...

Page 129: ... 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 Remove tool T1 See drawing T1 p 131 together with the pin 9 of the planetary gear FIGURE 11 Leave the released planetary gear in position and again lock tool T1 See drawing T1 p 131 Repeat the operatio...

Page 130: ...ng 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 planetary gears 7 Line up the entire unit by pushing bar T3C See drawing T3 p 132 all the way down until press tool T3A See drawing T3 p 132 is ejected FIGURE 17 Lock tool T1 See drawing T1 p 131 behind...

Page 131: ...6B 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 ring centers the seat and that it rests on the surface of the differential carrier Repeat the operations on the other planetary pins FIGURE 23 Position the second planetary gear 6 in the dif ferential...

Page 132: ...n 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 26 Install the bearings 3 and 4 using tool T4 See drawing T4 p 132 1 2 12 T17 T17 T4 T4 3 4 ...

Page 133: ...025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3708 0 8 0 8 0 8 0 8 x45 1 Ø41 Ø25 Ø20 0 2 0 26 18 36 5 20 Ø5 5 R 1 M26X1 5 9 6 33 Ø25 Ø41 Ø20 0 2 0 6 Ø5 5 22 5 10 5 x45 1 31 P N 3424 0 8 0 8 Ø30 0 1 0 2 Ø27 0 08 0 12 Ø20 5 8 5 24 5 0 0 1 Ø23 15 ...

Page 134: ...0025E 212 Axle Service Manual T3 T4 P N 2306 5 8 2 Ø 46 45 10 56 6 x30 3 9 9 1 Ø Ø 0 3 2x30 10 29 6 Ø 6 19 6 x45 0 5 x30 1 175 9 9 1 Ø 9 9 1 Ø 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 0 1 0 2 Ø38 5 Ø55 Ø63 Ø65 38 68 3 1 x45 1 5 ...

Page 135: ...ion 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 15 14 16 7 15 13 16 14 6 7 ...

Page 136: ...own 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 4 3 5 4 FIGURE 4 Remove the planetary gear 6 and the whole fric tion unit 7 FIGURE 5 If bearing 8 needs replacing extract it from the differential unit 9 FIGURE 6 Remove the snap rings 10 from the p...

Page 137: ...awing 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 T3A See drawing T3 p 141 and bushing T2 See drawing T2 p 140 NOTE In this state the pin 11 is contained within tool T1 See drawing T1 p 140 FIGURE 11 Remove tool T1 See drawing T1 p 140 and pla netary...

Page 138: ...on 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 whole friction assembly concerned 7 9 7 6 ...

Page 139: ... 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 discs 14 and friction discs 15 alternated outer disc 16 and spacer 17 As to rings 13 and 16 the side without notches must face outwards FIGURE 17 Position shim washer 18 and the first planetary gear 12 H...

Page 140: ...hind 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 unit 9 under the press position bushing T2 See drawing T2 p 140 and insert the planetary pin 11 FIGURE 23 Place press tool T3B See drawing T3 p 141 on top of the planetary pin 11 FIGURE 24 Press pres...

Page 141: ...he 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 towards the protrusions of the braking unit Position the crown 4 on the differential unit 9 and lock it with the screws 3 previou sly coated with Loctite 242 Torque wrench setting for screws 128 142 N ...

Page 142: ...025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3708 0 8 0 8 0 8 0 8 x45 1 Ø41 Ø25 Ø20 0 2 0 26 18 36 5 20 Ø5 5 R 1 M26X1 5 9 6 33 Ø25 Ø41 Ø20 0 2 0 6 Ø5 5 22 5 10 5 x45 1 31 P N 3424 0 8 0 8 Ø30 0 1 0 2 Ø27 0 08 0 12 Ø20 5 8 5 24 5 0 0 1 Ø23 15 ...

Page 143: ...0025E 212 Axle Service Manual T3 T4 P N 2306 5 8 2 Ø 46 45 10 56 6 x30 3 9 9 1 Ø Ø 0 3 2x30 10 29 6 Ø 6 19 6 x45 0 5 x30 1 175 9 9 1 Ø 9 9 1 Ø 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 0 1 0 2 Ø38 5 Ø55 Ø63 Ø65 38 68 3 1 x45 1 5 ...

Page 144: ...142 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 145: ...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 146: ...ove 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 selector fork 5 by ap proximately 2 turns FIGURE 5 Using a metal punch and a hammer disengage selector fork 5 from piston cone 6 FIGURE 6 Using two wrenches lock piston 6 and remove nut 4 5 4 5 6 6 ...

Page 147: ...r 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 ring 11 and o ring 10 NOTE The guide ring 11 and o ring 10 must be replaced each time the unit is disassembled FIGURE 12 Remove snap ring 9 and take piston unit 6 apart Remove all component parts 6 12 ...

Page 148: ... 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 For details see DIFFERENTIAL UNIT p 61 16 19 18 17 20 15 21 ...

Page 149: ...7 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 piston 6 Lubricate seals and insert the assembly into tool T1 See drawing T1 p 149 FIGURE 19 Insert tool T1 See drawing T1 p 149 in the cen tral unit 22 and push the piston 6 into the seat Remove tool T...

Page 150: ...in 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 Carefully check the state of the o ring 23 FIGURE 25 Install the lock nut 4 of the selector fork 5 and lock it with a torque wrench set to a torque of 70 75 N m FIGURE 26 Install the security switch 2 c...

Page 151: ...olding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 T2 P N 3543 Ø33 Ø26 0 08 0 12 Ø28 0 08 0 12 Ø24 10 30 50 3x15 5 15 Proteggere da cementazione 0 8 0 8 P N 2316 18 M12x1 25 17 35 0 2 0 1 Ø17 Ø16 2 0 0 1 15 ...

Page 152: ...150 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 153: ...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 154: ...of 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 screws 17 DANGER FIGURE 3 Remove arm together with brakes and axle shafts lay down the arm vertically Release pressure FIGURE 4 Remove the reversal springs 12 from the cover 11 FIGURE 5 Remove the pin sc...

Page 155: ...f 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 low pressure compressed air through the connection member for the service brake in or der to extract the piston 10 Hold the piston 10 back as it may be suddenly ejected and damaged 7 2 10 CAUTION ...

Page 156: ...re 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 brake discs 14 and 15 writing down direction of assembly NOTE If disks are not to be replaced avoid changing their position FIGURE 15 Remove braking discs 16 and shims 24 wri ting down direction of assem...

Page 157: ...mer 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 Using a plastic hammer insert the piston 10 into the cylinder 7 NOTE Lightly hammer all around the edge in an alternate sequence FIGURE 20 Apply grease and position the Belleville washers 2 and engage...

Page 158: ...ative 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 relative centering 2 1 7 7 FIGURE 24 Lock the cylinder FIGURE 25 Tightening the studs with a torque wrench set to a torque of 30 45 N m FIGURE 26 Fill with ATF oil For details see ADJUSTMENT AND CHECKS...

Page 159: ...atic 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 to the thread of the pistion adjustment nut Tighten with torque wrench setting of 10 15 N m FIGURE 32 Y brake gap 0 75mm 1 00mm 1 25mm 1 50mm Depending on axle configuration 11 12 13 10 15 N m Y 18 ...

Page 160: ... 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 including the shim under a press load with 1000 kg and take the measure V EXAMPLE V 40 mm 5 7 N m FIGURE 36 Arm fix quote 68 mm FIGURE 37 S 68 mm x y v Thickness of shims to insert under the shim washer 24 ...

Page 161: ...il 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 arm s o ring install the complete arm NOTE To assist axle shaft centering slightly move the wheel hub B 14 FIGURE 40 Torque wrench setting A 200 N m B 283 N m NOTE Tighten using the criss cross method ...

Page 162: ...160 ASSEMBLY Dana Holding Corporation ASM 0025E 212 Axle Service Manual ...

Page 163: ...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 164: ... 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 FIGURE 4 Remove the upper flange 1 together with dust ring 5 FIGURE 5 Remove the snap ring 6 and discard it FIGURE 6 Remove the lower flange 2 1 5 6 2 ...

Page 165: ...d 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 gear 11 7 8 9 10 9 11 9 11 FIGURE 10 Lightly tap with a hammer to disengage cover 9 from upper gear 12 FIGURE 11 Draw out cover 9 and remove any sealant left FIGURE 12 Remove lower gear 13 9 9 12 13...

Page 166: ...IGURE 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 side of the intermediate cover 17 Remove the complete arm For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 FIGURE 18 Remove the intermediate cover 17 and the whole differential unit ...

Page 167: ...0 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 in the central body 11 FIGURE 23 Remove the complete pinion 20 NOTE Carefully check and note direction of installation of spa cer FIGURE 24 Using a punch and a hammer extract the snap ring 25 NOTE N...

Page 168: ...y 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 insert the complete pinion assembly 20 FIGURE 28 Apply Loctite 242 to the thread of the pinion and screw the ring nut 19 Engage special wrench T1 See dra wing T1 p 169 on the ring nut and apply bar ho...

Page 169: ...REPLACING 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 outer bearing and the gear CAUTION 14 12 CAUTION 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 33 Fit the lower gear 13 onto th...

Page 170: ... 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 the threaded portion of pinion 20 and upper gear 12 Fit o rings 4 and nuts 3 9 12 10 8 9 7 20 1 2 3 4 FIGURE 38 Apply tool T6A See drawing T6 p 174 or T6B to flanges 1 and 2 and tighten nuts 3 using a ...

Page 171: ...SPECIAL TOOLS 169 Dana Holding Corporation ASM 0025E 212 Axle Service Manual SPECIAL TOOLS T1 0 8 0 8 3 4 Ø15H7 n6 0 08 0 12 Ø55 Ø75 35 x15 5 60 15 14 34 32 25 ...

Page 172: ...170 SPECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual T2 0 8 Ø85 Ø55H7 7 60 Ø66 22 75 10 6 20 40 20 6 60 100 275 15 ...

Page 173: ...SPECIAL TOOLS 171 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T3 0 8 0 8 Ø35 0 1 0 2 Ø50 Ø25 Ø64 50 x15 3 0 0 2 3 13 50 150 213 52 x15 5 R 1 5 R 1 0 x45 2 ...

Page 174: ...ing Corporation ASM 0025E 212 Axle Service Manual T4 T4C T4B T4A 64 Ø40H8 Ø54 Ø70 M18X1 5 50 267 312 5x15 M18X1 5 Ø40H8 30 17min R3 R3 23 3x15 Ø40 Ø55 Ø83 0 08 0 12 Ø89 56 10 66 2 1 R2 R 2 R2 1 5 0 0 2 Ø19 0 8 0 8 0 8 0 8 0 8 0 8 ...

Page 175: ...SPECIAL TOOLS 173 Dana Holding Corporation ASM 0025E 212 Axle Service Manual T5 0 8 0 8 2x15 2x45 5x45 R5 Ø55 Ø60 0 2 0 3 Ø72 0 2 0 3 Ø30 30 130 1 10 12 152 ...

Page 176: ...ECIAL TOOLS Dana Holding Corporation ASM 0025E 212 Axle Service Manual T6 80 0 2 Ø105 120 15 0 2 Ø105 25 25 10 Ø50 0 2 Ø185 0 0 2 Ø34 5 125 125 61 5 100 15 10 Ø45 126 150 12 61 5 73 97 85 135 0 5 Ø32 T6A T6B ...

Page 177: ......

Page 178: ...ine 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 means electronic or otherwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES ...

Page 179: ......

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