ALLCV

Service Manual
Rear Axle C100/RS120
06.02 REAR AXLE C100/RS120

CONTENTS

CHAPTER - 06

REAR AXLE C100/RS120

Section Subject Page No.

06.0 General ..................................................................................................................... 06.3

06.0.0 Rear Axle Type and Sl. No. ............................................................................................... 06.3
06.0.1 Design and Operation ........................................................................................................... 06.3
06.0.2 Description of Leading Components ............................................................................... 06.3
06.0.3 Data ............................................................................................................................................... 06.4
06.0.4 Rear Axle Preliminary Checks ........................................................................................... 06.6

06.1 Rear Axle Removal and Fitment ....................................................................... 06.8

06.2 To Remove and Refit Differential Carrier & Overhaul ............................... 06.9

06.3 Installation of Differential Carrier with Axle Housing ............................... 06.25

06.4 Repair Welding of Housing ................................................................................ 06.26

06.5 Special Tools ........................................................................................................... 06.27

06.6 Tightening Torques ............................................................................................... 06.29

06.7 Filling Capacity ....................................................................................................... 06.30

06.8 Recommended Lubricants .................................................................................... 06.30

06.9 Maintenance Schedule .......................................................................................... 06.30

 REAR AXLE C100/RS120 06.03

06.0 GENERAL

06.0.0 Rear Axle Type and Sl. No.

AL rear axle type and serial number are

punched on the LH side top doom area.

The AAL Identification plate in riveted on

LH rear side of Rear Axle Casing. Fig - 1

Fig. 1

06.0.1 Design and Operation End assemblies

Final drive to road wheels is taken through
The rear axle is a fully floating pressed type
the axle shafts connected to the hubs
banjo axle with a hypoid differential carrier
mounted on two opposed tapered roller
(Single reduction carrier without differential
bearings at the end of both axle tubes.
lock).

The single reduction carrier models are front 06.0.2 Description of Leading Components
mounted into the axle housing. These
carriers have a hypoid drive pinion and ring Rear axle casing - of AAL make,
gear set and bevel gears in the differential pressed steel in banjo shape to house
assembly. differential carrier (AAL supply), axle shaft
Straight roller bearing (Spigot) is mounted on and hub ends.
the head of the drive pinion. All other
bearings in the carrier are tapered roller Differential cage assembly - supplied
bearings. The pinion shaft flange is serrated. as part of differential carrier by Automotive
Axles Ltd.
When the carrier operates, there is normal
differential action between the wheels all the
Crown wheel pinion - Hypoid type
time.
lower pinion axis w.r.t. crown centre
enables better lubrication and higher load
Differential Assembly
carry capacity.
The pinion shaft is mounted on preloaded
taper roller bearings and housed in the
Differential carrier - supplied as sub
lower half of the differential carrier. The
assembly along with casing by AAL
ring gear and main differential assembly runs
(Automotive Axles Ltd.).
on taper roller bearings and is secured in
the casing by the bearing caps, adjustment
Axle shaft - of forged alloy steel heat
for backlash and tooth contact is by the
treated with machined splines at one end
adjuster-nuts for the ring gear and by shims
and flange at other end.
for the pinion. The pinion oil seal prevents
ingress of dirt and loss of lubricant to the
Hub ends - of spheroidal cast iron
bearings. The whole differential assembly is
machined to accommodate inner / outer
secured to the axle by studs and nuts. The
wheel bearings, oil seals, wheel bolts. The
pinion shaft flange is serrated.
hub has spigot dia to locate brake drum,
wheel rims.
06.04 REAR AXLE C100/RS120

06.0.3 Data C100 RS120

Type Fully floating single reduction carrier
Axle Weight Rated kgs 5000 7500
Pinion Input Torque kgm
Arm Section ( Depth X Width X Thick) mm 108 x 97 108 x 97
Bowl Diameter mm 306 306
Ring Gear Size mm 304.8 337
Gear PCD mm 304.8 336.5
Crown Wheel Pinion Backlsh - Reused mm 0.20-0.46 0.20 - 0.46
Crown Wheel Pinion Backlsh - New mm 0.3 0.3
Diff Side Bearing ID mm 63.5 77.788/66.675
Diff Side Bearing OD mm 110 121.442/110
Diff Side Bearing Width mm 22 24.608/30.612
Pinion Bearing ID-INNER mm 41.275 50.8
Pinion Bearing OD—INNER mm 92.075 111.125
Pinion Bearing Width—INNER mm 26.195 30.162
Pinion Bearing ID-OUTER 36.512 47.625
Pinion Bearing OD—OUTER 88.501 95.25
Pinion Bearing Width—OUTER 25.4 30.162
Crown Wheel Lateral Runout/face out mm 0.2 0.2
Pinion Bearing Preload kg 1.0-3.5 1.0-3.5
Diff Side Bearing Preload lb. ft. 15-35 15-35
Axle Shaft Dia mm 35 42
Available Ratios 4.33/4.56/5.29 6.14
Axle shaft splines 38 x 37 T 45 x 34 T
Oil Capacity Lits 6 6.5
Spring Track mm 1001 1029
Wheel Track mm 1617 1700
Spring Pad Width 108X97 108X97
Wheel Bearing Seating -inner Dia On Casing 73.001 76.157
Wheel Bearing Seating -outer Dia On Casing 63.476 63.457
Wheel Bearing Inner - OD 5.000"
Wheel Bearing Inner - ID 2.875"
Wheel Bearing Inner - Interference Fit On Casing mm 0.000 - 0.005 0.000 - 0.005
Wheel Bearing Inner - Interference Fit On Hub mm 0.000 - 0.005 0.000 - 0.005
Wheel Bearing Outer - ID 2.5000"
Wheel Bearing Outer - OD 4.4375"
Wheel Bearing Outer - Interference Fit On Casing mm 0.000 - 0.005 0.000 - 0.005
Wheel Bearing Outer - Interference Fit On Hub mm 0.000 - 0.005 0.000 - 0.005
Thrust Screw Clearence mm 0.65 - 1.14 0.65 - 1.14
Hub End Play mm 0.025 - 0.076 0.025 - 0.076
 REAR AXLE C100/RS120 06.05

Fig. 2 - Exploded View of Rear Axle C100 & RS120

ILL. NO. DESCRIPTION QTY.

1 AXLE HOUSING ASSY 1
2 BREATHER ASSY 1
3 MAGNETIC DRAIN PLUG 1
4 DIFF CARRIER ASSY 1
5 GASKET - CARRIER TO HOUSING 1
6 CAP SCREW-LONG 9
7 STUD 3
8 WASHER -CARRIER TO HSG 12
9 PLUG OIL FILLING 1
10 NUT DRIVE PINION 1
11 WASHER DRIVE PINION 1
12 COMPANION FLANGE 1
13 DEFLECTOR COMPANION FLANGE 1
14 OIL SEAL PINION 1
15 PINION OUTER BRG 1
16 PINION CAGE,CUP&CONE ASSY 1
17 CAP SCREW-PINION CAGE 8
18 WASHER 8
19 SHIM PINION BRG GAUGE 1
20 SPACER KIT DRIVE PINION 1
21 PINION INNER BRG 1
22 DRIVE GEAR & PINION ASSY 1
23 SPIGOT BEARING DRIVE PINION R/A 1
24 LOCK RING 1
25 DIFF.CARR.& CAP ASSY 1
26 SCREW THRUST 1
27 NUT SPECIAL 1
28 CAP SCREW DIFF.BRG CAP 4
29 WASHER DIFF.BRG.CAP 4
30 ADJUSTING RING 2
30A COTTER PIN-ADJ RING 2
32 DIFF BEARING R/A 1
35 DIFF CASE 1
39 THRUST WASHER -SIDE GEAR 2
40 SIDE GEAR DIFF 2
41 THRUST WASHER DIFF.PINION 4
42 PINION -DIFF 4
43 SPIDER DIFF 1
44 WASHER DIFF CASE 12
45 NUT DIFF CASE TO GEAR 12
06.06 REAR AXLE C100/RS120

06.0.4 Rear Axle Preliminary Checks

It is mandatory to carry out few preliminary check on rear axle before dismounting from the vehicle. The
following cause and effects can lead to overhauling decision.

Oil
Preventive Loss of bearing
leakage from
maintenance preload
dome area

REAR AXLE
OVERHAULING

Mechanical No power
noise transmitted

Fig. 3 Cause and Effect Diagram - Rear axle overhauling

Prolonged
Maintenance
Operation
Insufficient
lubrication (Quality, Worn-out
Quantity & Gears
Contamination Worn-out
Foreign bearings
Material Worn-out
inside thrust
Propeller shaft washers Worn-out
flange bolts loose differential
gears
Differential
carrier
nuts loose
NOISE FROM
DIFFERENTIAL

Poor backlash
(Humming Crown and
noise) Pinion
Over Mismatch
backlash
(Grinding Non genuine
Less preload noise) parts
on crown
bearings

Method Material

Fig. 4 Cause and Effect Diagram - Noise from Differential

 REAR AXLE C100/RS120 06.07

Method Material

Distance piece Poor

parallelism not Quality
maintained Bearing

Insufficient Non
torque Genuine
tightening parts

Correct amount of Wear on

preload not set Bearings
LOSS OF
PRELOAD PINION
BEARINGS
Pinion nut not Not using spring
tightened balance to check
periodically preload

Technicians not
trained properly
Lack of lubrication
(Over heating)

Maintenance Others

Fig. 5 Cause and Effect Diagram - Loss of Preload Pinion Bearings

Method Material

Shim Foreign
selection material
wrong inside
Improper
Preload Stuck up
ring nut
Improper tooth Crown & Pinion
contact unmatched set
Improper
backlash
Inadequate training of Nose bearing
technicians in setting not fitted
crown and pinion CROWN WHEEL
AND PINION
TEETH BREAKAGE
Insufficient
lubrication
(Quantity, Quality
& Contamination)

Bearing seizure

Pinion shaft nut

not tightened
periodically

Maintenance Others

Fig. 6 Cause and Effect Diagram - Crown Wheel and Pinion Teeth Breakage
06.08 REAR AXLE C100/RS120
06.1 REAR AXLE REMOVAL AND
FITMENT
Removal
* Apply the parking brake, chock the front
wheels and disconnect the battery.
* Slacken the rear wheel nuts.
* Raise the rear of the vehicle and support it
with chassis stands placed forward of the
rear axle and at sufficient height to allow the
axle to hand unsupported with the wheels
just clear of the ground.
* Drain the rear axle oil.
* Disconnect the drive shaft and support it
clear off the axle.
* Remove the road wheels from both sides of
the rear axle using a suitable wheel trolley.
* Support the rear axle on a transmission jack
and cradle or on a suitable trolley jack,
partly compressing the rear springs to relieve
any weight from the shock absorbers and
"U" bolts.
* Secure the axle to the jack with a tie chain.
* On full air brakes disconnect the flexible
pipes from the union block.
* Disconnect both lower shock absorber
retaining bolts, and swing them clear of the
axle.
* Remove the "U" bolts and the top clamp
plates.
* Carefully lower the axle away from the
springs and withdraw the assembly from
under the vehicle.
* Retain any spacer plates (where fitted) and
locating dowels for reassembly.
Cleaning and Inspection
The actual amount of cleaning and inspection
required when removing a complete axle
depends on whether the reason for its
removal for further attention to the axle
itself or to the rear of the vehicle. The
following points should be observed before
refitting the axle to the vehicle.
* Ensure the mating faces of the springs the
plates and spacers when fitted are cleared.
* Renew all self-locking nuts and split pins.
Rear Axle Installation
* Support the axle on a transmission jack and
cradle, or on a suitable trolley jack and
locate the axle into position under the rear
of the vehicle.
* Locate the spacer plates (where fitted), and
locating dowels when fitted, onto the axle
pads and carefully raise the axle to the
springs ensuring the dowels and/or spring
centre bolts are correctly aligned.
* Raise the jack to partially compress the
rear springs.
* Fit the spring top plates (where fitted) and
the "U" bolts. Do not fully tighten at this
stage.
* Fit the "U" bolts nuts and securely tighten
progressively and evenly.
CAUTION: If new springs, "U" bolts, and / or
"U" bolts nuts have been fitted the
torque should be checked in
accordance with the Service Schedule,
as if for a new vehicle.
* Reconnect the shock absorbers and tighten
the retaining bolts and nuts to the specified
torque.
* Connect the drive shaft and tighten the
securing nuts and bolts to the specified
torque.
* Refit the rear wheels and securely tighten
the wheel nuts.
* Remove the chassis stands and lower the
rear of the vehicle to the ground.
* Tighten the "U" bolts nuts to the specified
torque.
* Tighten the axle drain plug to the specified
torque, fill the axle to level with the
specified oil and tighten the level plug to
the specified torque.
* Reconnect the batteries and run the engine
to charge the air reservoirs.
* Apply the parking brake and remove the
chocks from the front wheels.
* Road test the vehicle until the axle reaches
normal operating temperature and check for
any extraneous noises.
* Check and torque the "U" bolts nuts and
the road wheel nuts.
* After road test, check for freedom from oil
leaks and top up the oil level if necessary.
CAUTION: The road wheel nuts should be
checked and retorqued again after
approximately 250 kms.
 REAR AXLE C100/RS120 06.09

06.2 TO REMOVE AND REFIT DIFFERENTIAL

CARRIER & OVERHAUL

Raise the rear end of the vehicle by using

suitable jack.

Put on jack stands. Fig - 1

Fig. 1

Disconnect the propeller shaft from input

flange.

Remove drain plug and drain differential oil.

Remove nuts and washers from the axle

shafts.

Loosen the taper dowels using brass drift

and hammer. Fig - 2

Fig. 2

Remove axle shafts using puller screws.

Remove all the carrier mounting fasteners.

Remove the carrier from the housing.

Mount the carrier on a repair stand. Use

SME No. 05006 - Stand for Drive Head
Assembly. Fig - 3

Fig. 3
06.10 REAR AXLE C100/RS120

Dismantling of Differential Carrier

Assembly

If the same gear set is to be reused record

the backlash before disassembly. Fig - 4

Fig. 4

Remove thrust screw and jam nut. Fig - 5

Fig. 5

Make match marks on one carrier leg and

bearing cap. Fig - 6

Fig. 6

Remove cotter pins using a small drift and

hammer. Fig - 7

Fig. 7
 REAR AXLE C100/RS120 06.11

Remove cap screws and washers of bearing

caps. Fig - 8

Remove bearing adjusting rings.

Fig. 8

Lift the differential case and ring gear

assembly. Fig - 9

Fig. 9

Make match marks on the differential case

halves. Fig - 10

Fig. 10

Remove the lock wires and differential case

bolts.

Separate case halves.

Remove spider, pinions, side gears and

thrust washers. Fig - 11

Fig. 11
06.12 REAR AXLE C100/RS120

Remove the gear mounting bolts and lock

plates.

Remove the ring gear from differential case

using a press. Fig - 12

Fig. 12

Remove the bearings from differential case

using bearing puller/press. Fig - 13

Fig. 13

Fasten a flange bar to the companion flange.

Remove pinion nut and washer. Fig - 14

Fig. 14

Remove the companion flange using a

suitable puller.

Remove cap screws and washers of bearing

cage.

Remove bearing cage and shims. Fig - 15

Measure and note down the total thickness

of removed shims.

Fig. 15
 REAR AXLE C100/RS120 06.13

Remove drive pinion from bearing cage using

a press. Fig - 16

Fig. 16

Remove the oil seal. Fig - 17

Fig. 17

Take out the outer bearing cone.

Remove the bearing cups from the cage

using a small drift and hammer.

Remove the inner bearing cone using the

split puller and press. Fig - 18

Fig. 18

Remove the snap ring.

Remove the spigot bearing using Special

Tool 0507004 - Puller Spigot Bearing.
Fig - 19

Fig. 19
06.14 REAR AXLE C100/RS120

Cleaning and Inspecting of Parts

Use kerosene or diesel to wash the parts.

Dry the parts immediately after cleaning.

Apply axle lubricant/rust preventive over the

reusable parts to prevent rust and corrosion.

Inspect roller bearings replace if any of the

following conditions exist.

i. Centre of bigger end of rollers worn

to the level or below the outer
surface. Fig. 20

ii. Radius at the bigger end of the rollers

worn out sharply. Fig - 20

iii. Bright wear mark on the outer surface

of roller cage. Fig - 21

Fig. 21

iv. Etching and pitting marks on roller

and on contact surfaces. Fig - 22

Fig. 22

v. Spalling and flaking marks on the cup

and cone inner race surfaces. Fig -
23

Fig. 23
 REAR AXLE C100/RS120 06.15

Inspect the following parts for wear or

stress.

i. Inside surfaces of differential case

halves. Fig - 24

Fig. 24

ii. Both surfaces of all thrust washers.

Fig - 25

iii. Four trunnion ends of spider.

iv. Teeth and splines of side gear.

v. Teeth and bore of differential pinions.

Fig. 25

Assembling of Carrier
Before installing a new gear set ensure set
number etched on the ring gear and the
drive pinion are same.
Location of marks are as shown in Fig - 26
a) Tooth combination number
b) Set number
c) Part number
d) Pinion cone variation number
Fig. 26

Press inner and outer bearing cups into

bearing cage using correct sleeves. Fig -
27

Fig. 27
06.16 REAR AXLE C100/RS120

Press the inner bearing cone on the pinion

till its sits firmly. Fig - 28

Fig. 28

Press the spigot bearing on the drive pinion.

Fig - 29

Fig. 29

Install the snap ring into the groove. Fig -

30

Fig. 30

Position the bearing cage over inner bearing

cone.

Apply axle lubricant on bearings.

Install the bearing spacer.

Press the outer bearing cone on the pinion

till it sits firmly on the spacer. Fig - 31

Fig. 31
 REAR AXLE C100/RS120 06.17

Check and correct preload of pinion

bearings. Adopting following procedure.

Place the pinion case assembly in a press.

- Install a sleeve on outer bearing.

- Apply 30,000 lb. (15 tons) pressure.

- While pressure is held, wind a cord around

the cage with the spring scale. Fig - 32
(If the press is not available install
companion flange and tight pinion nut to the
torque of 300 - 400 lb. ft.) Fig. 32

Pull the cord on horizontal line. As the

cage rotates read the scale. Spring scale
read between 1 - 3.5 kg.

If the scale reading is not within the

specifications.

a) To increase preload reduce bearing

spacer thickness.

b) To reduce preload increase bearing

spacer thickness.

Apply grease to the oil seal lips and the

cavity between lips.

Use a mallet and the sleeve to install the

seal. Fig - 33

Install washer and pinion lock nut tighten

the pinion nut to the torque of 300-400
lb.ft.

If original gear set is reused install the

original shim pack.

If new gear is used, to arrive at correct Fig. 33

mounting distance of drive pinion adopt
following procedure.

a) Note pinion cone variation no. etched

on removed gear.

b) If this is a plus(+), substract (-) the

no. from old shim pack thickness
(or)
If it is minus (-), add (+) the no. to
old shim pack thickness.

c) The value arrived as above, is the

thickness of standard shim pack.
06.18 REAR AXLE C100/RS120

d) If pinion cone variation no. of new

gear set is minus (-), substract the no.
from standard shim pack arrived as
above.
(or)
If it is plus(+), add to standard shim
pack thickness.

Refer examples - chart 1 

Install pinion bearing cage assembly with the

new shim pack, calculated above with the
differential carrier.
Fig. 34
Align the capscrews with the above shim
pack with the bearing lub hole on the
differential carrier. Fig - 34

Torque tighten capscrews uniformly and

alternatively so that pinion cage sits firmly.

Chart - 1
Inches mm
Example 1:
Old Shim Pack Thickness 0.030 0.76
Old PC Number, PC + 2 – 0.002 – 0.05
Standard Shim Pack Thickness. 0.028 0.71
New PC Number, PC + 5 + 0.005 + 0.13
New Shim Pack Thickness 0.033 0.84

Example 2:
Old Shim Pack Thickness 0.030 0.76
Old PC Number, PC – 2 + 0.002 + 0.05
Standard Shim Pack Thickness 0.032 0.81
New PC Number, PC + 5 + 0.005 + 0.13
New Shim Pack Thickness 0.037 0.94

Example 3:
Old Shim Pack Thickness 0.030 0.76
Old PC Number, PC + 2 – 0.002 – 0.05
Standard Shim Pack Thickness 0.028 0.71
New PC Number, PC – 5 – 0.005 – 0.13
New Shim Pack Thickness 0.023 0.58

Example 4:
Old Shim Pack Thickness 0.030 0.76
Old PC Number, PC – 2 +0.002 +0.05
Standard Shim Pack Thickness 0.032 0.81
New PC Number, PC – 5 – 0.005 – 0.13
New Shim Pack Thickness 0.027 0.68
 REAR AXLE C100/RS120 06.19

Heat the ring gear in a water/oil bath to

about 170°F (80°C) for 15 minutes.

Install the ring gear on flange half

immediately aligning mounting holes. Fig -
35

Install mounting bolts, washers and nuts.

Tighten the bolts to the recommended

torque.
Fig. 35
Install the bearing cones on both differential
cases

Install spider, side gear, differential pinions

and thrust washers into flange half.

Install plain half aligning match marks. Fig -

36

Tighten the differential case bolts as

recommended.

Fig. 36

Check the rotating resistance of differential

gears. Fig - 37

Recommended torque is 5 - 20 lb. ft.

If torque is more, check case halves, spider,

differential gears thrust washers. Replace the
parts as necessary.

Fig. 37

Apply adhesive to bearing bores. Fig - 38

Fig. 38
06.20 REAR AXLE C100/RS120

Install differential assembly into the carrier

Install both side adjusting rings and hand

tighten till these touches the differential side
bearings. Fig - 39

Fig. 39

Install the bearing caps aligning the match

marks.

Tighten the bearing cap bolts until the bolt

head sits on the bearing caps. Fig - 40

Fig. 40

Attach a dial indicator so that the plunger is

against the back face of the ring gear. Fig
- 41

Fig. 41

Move the differential to the left and right

with pry bars and ensure small amount of
end play. Fig - 42

Fig. 42
 REAR AXLE C100/RS120 06.21

Tighten the adjusting ring opposite to ring

gear till the indicator shows zero end play.
Fig - 43

Fig. 43

Tighten both adjusting rings one notch to

preload the differential bearings.

Adjust dial indicator to zero.

Rotate the ring gear to check the run out.

Run out should be within 0.008" (0.20mm)

Fig - 44

Fig. 44

Position the dial indicator so that the

plunger is on the drive side of the tooth.
Fig - 45

Adjust the backlash by loosening the one of

the adjusting rings and tightening the other
adjusting ring to the equal amount.

Backlash specification:

Backlash range = 0.008" - 0.018" Fig. 45

(0.20 - 0.46 mm)

Backlash for new

gear set = 0.012" (0.30 mm)

While reusing old gear set adjust the

backlash noted during dismantling.

To increase backlash move the ring gear

away from the drive pinion. Fig - 46

Fig. 46
06.22 REAR AXLE C100/RS120

To decrease backlash move the ring gear

towards the drive pinion. Fig - 47

Fig. 47

Apply marking compound to six teeth of

ring gear.

Rotate the ring gear forward and backward

so that these teeth go past pinion to obtain
clear pattern. Fig - 48

Fig. 48

Compare the contact pattern to Fig - 49,

50 and 51.

Good contact pattern - towards the toe

of the gear teeth and in centre between top
and bottom of teeth. Fig - 49

Fig. 49

High pattern - this indicates that the drive

pinion is not installed deep enough into the
carrier. Fig - 50

Fig. 50
 REAR AXLE C100/RS120 06.23

Low pattern - this indicates that the drive

pinion is installed too deep in the carrier.
Fig - 51

Fig. 51

To correct the pattern proceed as follows.

High pattern - decrease the thickness of

shim pack under bearing cage. This will
move the pinion towards ring gear. Fig -
52a

Low pattern - increase the thickness of

shim pack under bearing cage. This will
move the pinion away from ring gear. Fig -
52b
Fig. 52a Fig. 52b

Location of patterns - to move the

contact patterns to the correct location in
the length of teeth, adjust the backlash
within specified range as follows. 
Fig. 53a

To shift the pattern towards toe of the

teeth to decrease the backlash. Fig - 53a

To shift pattern towards heel of the teeth

to increase backlash. Fig - 53b
Fig. 53b

Tighten the bearing cap bolts to the

recommended torque.

Fig. 54
06.24 REAR AXLE C100/RS120

Install the cotter pins in the adjusting rings

using a drift and hammer. Fig - 55

Fig. 55

Install the thrust screw and tighten until it

touches the ring gear.

Loosen the thrust screw ½ turn (180"). Fig -

56. Clearance between thrust screw and ring
gear should be 0.025" - 0.045" (0.65 - 1.14
mm)

Tighten jam nut to the recommended torque.

Fig. 56

Clean the housing mounting face. Remove

the old gasket material.

Apply silicon gasket material uniformly on the

mounting surface of the housing. Fig - 57
Install the carrier into the housing.

Install washers, nuts and capscrews. Tighten

to the recommended torque.

Fig. 57

Install the gaskets and axle shafts. Fig - 58

Install the washers and cap screws and

tighten to the correct torque value.

Connect propeller shaft to the input flange.

Install drain plug and fill up with lubricant to

the required level.

Fig. 58
 REAR AXLE C100/RS120 06.25

06.3 INSTALLATION OF DIFFERENTIAL

CARRIER WITH AXLE HOUSING

Apply silicone gasket material / Anabond

666 to the mounting surface.

Install carrier into the axle housing.

Install washers / nut / capscrews holding the

carrier and tighten a pattern opposite each
other.

Install gaskets and axle shafts into the axle

housing and carrier. install fasteners and
tighten.
Fig. 1
Rear Hub Setting and End Play

Dismantling and Inspection

1. Remove the wheels and brake drum.

2. Remove axle shaft.

3. Loosen outer wheel bearing locknut &

pierced washer & inner nut.

4. Pull out hub along with outer bearing.

5. Remove inner bearing.

6. Clean, Inspect and replace worn out parts Fig. 2

and seals.

Hub Setting

- Repack inner, outer bearing and hub cavity

with grease.

- Pack the grease inside the hub.

- Place inner bearing in outer race. Install the

inner oil seal on the hub using bung and
hammer.

- Position the hub on the axle housing and fit

outer bearing (pre-greased) and fasten
adjusting nut to the bearing surface and
tighten to the torque (138 Nm).

- Loosen the nut and retighten to torque (69

Nm)

- Back-off adjusting nut by 1/6 to 1/4 turn.

- Ensure the end play within 0.025 mm -

0.076 mm.

- If the end play is not within limits, adjust the

nut for required end play.

- Locate the washer in adjusting nut dowel

and fit lock nut. Tightening torque of the
lock nut is 350 Nm.
06.26 REAR AXLE C100/RS120

06.4 REPAIR WELDING OF HOUSING

1. Repair weld is permitted only on the

areas of cover weld, seam weld, and
bracket welds.

2. Drain the lubricant from axle assy.

Remove axle shafts and differential
carrier.

3. Clean the cracked area inside and

outside the housing with a cleaning
solvent.

- Grind the damaged weld to the base

metal.

- Warm the complete housing to the

temperature of 70°F - 80°F (21°C to
27°C) or higher

- Heat the damaged area to

approximately 300°F (149°C).

- Use a 70,000 psi tensile weld rod of

4 to 5 mm diameter. Recommended
electrodes are SUPER CITO of Advani
Oerlikon and Supratherm of D & H.

- Opening in cover weld must be filled

to the level with old weld.

- Clean the new weld area, remove the

weld spatters.

- Install the differential carrier and axle

shafts.
 REAR AXLE C100/RS120 06.27

06.5 SPECIAL TOOLS

Special Tool 0101013 - Extractor Flange

Fig - 1

Fig. 1

Special Tool 0301007 - Holder Companion

Flange. Fig - 2

Fig. 2

Special Tool 0505001 - Restrainer Crown

Wheel Bolt. Fig - 3

Fig. 3

Special Tool 0505002 - Spanner Hub Nut.

Fig - 4

Fig. 4
06.28 REAR AXLE C100/RS120

Special Tool 0505003 - Drift Rear Hub Oil

Seal. Fig - 5

Fig. 5

Special Tool 0507012 - Differential Bearing

Puller. Fig - 6

Fig. 6

Special Tool 0505004 - Socket Flange Nut

for C100.

Special Tool 0506001 - Socket Flange Nut

for RS120.

SMT 3828 - Hub Puller rear.

 REAR AXLE C100/RS120 06.29

06.6 TIGHTENING TORQUES Kgm lb.ft Nm

C100 Rear Axle
Carrier to housing 10.4 - 12.4 75 - 90 102 - 122
Drive pinion nut 41.5 - 55.3 300 - 400 407 - 542
Differential Cage Assembly 10.4 - 12.4 75 - 90 102 - 122
Crown wheel to differential cage 11.8 - 15.9 85 - 115 115 - 155
Thrust screw jam nut 20.7 - 26.3 150 - 190 203 - 258
Differential cage side bearing cap screw 24.9 - 30.4 180 - 220 244 - 298
Differential gear rotating resistance 0.7 - 2.8 5 - 20 6.7 - 27
Pinion bearing cage screw 5.5 - 6.9 40 - 50 54 - 68
Brake assembly to axle casing 9.7 - 10.7 70 - 77 95 - 105
Axle shaft mounting nuts 5.1 - 7.1 37 - 52 50 - 70
Axle shaft mounting studs 6.4 - 7.9 46 - 57.52 63 - 78
Brake actuator mounting bolt 6 - 7 43 - 51 59 - 69
Brake drum mounting bolt 6 43 59

RS120 Rear Axle

Carrier to housing 10.4 - 12.4 75 - 90 102 - 122
Differential Cage Assembly 11.8 - 13.8 85 - 100 115 - 136
Crown wheel to differential cage 8.9 - 11.0 65 - 80 88 - 108
Thrust screw jam nut 20.7 - 29.0 150 - 210 203 - 285
Differential cage side bearing cap screw 24.9 - 30.4 180 - 220 244 - 298
Differential gear rotating resistance 6.9 50 68
Pinion bearing cage screw 10.4 - 12.4 75 - 90 102 - 122
Breather Assembly
Wheel nuts
Brake assembly to axle casing 9.7 - 10.7 70 - 77 95 - 105
Axle shaft mounting nuts 5.1 - 7.1 37 - 52 50 - 70
Axle shaft mounting studs 6.4 - 7.9 46 - 57.52 63 - 78
Brake actuator mounting bolt 6 - 7 43 - 51 59 - 69
Brake drum mounting bolt 6 43 59
 06.30 REAR AXLE C100/RS120

06.7 FILLING CAPACITY

Aggregates Filling Capacity (l)

C100 6

RS120 6.5

Hub grease quantity (one side)

06.8 RECOMMENDED LUBRICANTS

ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Ambient Sah
Indian Oil Hindustan Bharat Elf Karol Pennzoil Meguin
Aggregate Leyland Temp. Gulf Oil India IBP Castrol Chemoleums Petroleums
Corporation Petroleum Petroleum Lubricants Lubricants Quaker Oil India
Specification °C IPOL
® IBP Extra Meguin
Rear Axle API GL5 with Servo Gear HP Gear Oil MAK Tranself Turbo GL5 IPOL Gear Plus
-12 and Gulf Gear Special Hypoy B Hypo Gear Gear Oil
Hypoid Anglamol 99 Super Super SPIROL XHD Type B SAE 85W140 Syncro Plus Gear Super
above DB 85W140 Gear oil 85W140 XP 85W140 Premium XP
Drive Additive 85W140 (T) 85W140 85W140 85W140 (AL) XP 85W140 GL 5 85W140
85W140(A) 85W140
Wheel
® Multi All MP Meguin
Bearing** Gulf MP Servo MP Grease MAK IPOL MP M P Grease
IS 12203 -- Lex 2 purpose Purpose Grease -- Grease
(Front & Grease No.2 Grease MP No.2 UNIVEX A Grease No.2 No.2
Grease No.2 No. 2 MP 2
Rear)
** : Gulf crown LC3 (Gulf), Servo Gem RR3 (IOC), Lithon RR3 (HP) and IPOL Iplex RR3 (Sah Petroleums) can be used for 10-02-04
wheel bearings for longer wheel greasing intervals upto 48000 kms.

06.9 MAINTENANCE SCHEDULE

km x 1000
Lubricant

16000 km
8000 km
Weekly

Remarks
No. of
points

Every

Every
Every
Daily
PDI

A. Lubrication
1. Check oil level and top up O 1 ✓ ✓
2. Change oil when hot. Refill upto correct level O 1 ✓ 48
3. Repack the hubs with recommended grease G 2 ✓
B. Maintenance
1. Check and adjust hub end play. Check the ✓ ✓ At the time of
condition of hub bearing, replace if necessary. hub greasing.
2. Check the tightness of driving head nuts
and axle shaft nuts ✓
3. Check the condition of differential bearings,
Change if necessary 96