WNDJ en SD 00 Workshop Manual Axle

PART NO.
WNDJ-EN-SD-00
WORKSHOP MANUAL
Workshop Manual
Axle
Axle
URL:http://www.hitachi-c-m.com WNDJ-EN-SD-00
PRINTED IN JAPAN (K) 2015, 08

Corresponding Model
Model ZF Axle Parts No.

ZW180-5A MT-L 3085 II
ZW220-5A MT-L 3095 II
This book consists of the following items.
 REPAIR MANUAL
 Lubrication and Maintenance Instructions
REPAIR MANUAL
ZF – MULTITRAC
MT-L 3085 II / 3095 II
5871.529.002 en
REPAIR MANUAL
for ZF - Multitrac
MT-L 3085 II / 3095 II
IMPORTANT INFORMATION:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to
a current ZF production unit. Continuous technical upgrading of the ZF units and extensions
concerning design options may require differing operations which can be carried out by qualified
specialists without greater difficulties by means of the perspective views included in the
corresponding spare parts lists.
This disassembly and reassembly manual is based on the design level of a ZF production unit at
the time of issue of the manual.
ZF Friedrichshafen AG reserves the right to replace this disassembly and reassembly manual by a
successive edition at any time without advance notice. Upon request, ZF Friedrichshafen AG will
advise which edition is the latest one.
Any maintenance work is to be done in accordance with ZF’s Lubrication and Maintenance
Instructions (ZF-order no: 5871 529 902) and ZF’s List of Lubricants TE-ML 05!
The ZF list of lubricants is being continuously updated and can be obtained or viewed as follows:
- at all ZF plants
- at all ZF service organizations
- Internet www.zf.com
---------------------------------------------------------------------------------------------------------------------------------
CAUTION:
Observe the vehicle manufacturer’s instructions and specifications for the installation and
commissioning of the unit!
ZF Friedrichshafen AG
ZF Services
Donaustr. 71
D - 94034 Passau
Abt.: MAIP21
Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction
or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
With the reserve of technical modifications!
Design level 2010/10
4. Edition 2012/01
TABLE OF CONTENTS Chapter/Page
Preface 0/1
General 0/2 … 3
Labeling of identification plate 0/4
Examples of contact patterns for the Gleason gear tooth system 0/5 … 8
Conversion table 0/9
Denomination of standard dimensions 0/10
Tightening torques for screws 0/11
TOOLS WS/1 ... WH/5
Special tools WS/1 ... 10
Commercial tools WH/1 ... 5
DISASSEMBLY 1/1 ... 4/8
1. Disassembly output and brake 1/1 ... 7
2. Disassembly axle housing 2/1
3. Disassembly drive 3/1 … 3
4. Disassembly differentials 4/1 … 3

4.1 Disassembly multi-disk differential lock DHL-2400 4/1 … 3
4.2 Disassembly differential D-2400 4/4 … 6
4.3 Disassembly multi-disk differential lock DL-2400 4/7 … 8
REASSEMBLY 5/1 ... 8/12
5. Reassembly differentials 5/1 … 12

5.1 Reassembly multi-disk differential lock DHL-2400 5/1 … 5
5.2 Reassembly differential D-2400 5/6 … 8
5.3 Reassembly multi-disk differential lock DL-2400 5/9 … 12
6. Reassembly drive 6/1 … 9

6.1 Determination of shim to obtain a correct contact pattern 6/1 … 2
6.2 Reassembly of input pinion 6/2 … 4
6.3 Determination of shim for setting of bearing rolling torque and backlash 6/5 … 8
7. Reassembly axle housing 7/1 … 2
8. Reassembly output and brake 8/1 … 12

Corporate Division
Repair Manual Off-Road Driveline
Technology and Axle Systems
PREFACE
This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair
and maintenance work to be done on ZF units.
This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters and servicemen with the work on your ZF product
whose practical and theoretical training is constantly updated in our training school.
The Service Stations established by ZF Friedrichshafen AG all over the world offer you:
1. Permanently trained staff
2. Specified equipment, e.g. special tools
3. State-of-the-art genuine ZF spare parts
All work is done there with utmost care and reliability.
In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms
of the currently applicable contractual conditions.
Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred are excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.
This manual is based on the state-of-the-art at the time of printing.

It was prepared with utmost care in order to avoid errors.
However, we shall not be liable for any errors in figures or descriptions.
ZF Friedrichshafen AG
5871 529 002 0/1

Corporate Division
GENERAL
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the unit, ensure utmost cleanliness and excellent workmanship. Dismantle the unit only if
any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts which
were installed with seals by slight blows with a plastic hammer. Use suitable pulling devices for removing
parts being tightly installed on the shafts, such as bearings, bearing rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from
residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end
covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be
replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings,
thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with
worn or broken sealing lip must also be renewed. In particular, ensure that no chips or other foreign bodies
remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation:
NOTE: Only a heating furnace or an electric drier is permitted for heating parts such as bearings, housings,
etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.
CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual. Tighten
screws and nuts according to the enclosed standard table, unless otherwise specified.
When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves!
NEVER wash disks having organic friction linings (e.g. paper disks) since this would have an adverse effect on lining
adhesion.
Only dry cleaning is permitted (leather cloth).
DANGER
When using detergents, observe the manufacturer’s instructions regarding their handling.
5871 529 002 0/2

Corporate Division
Structure of the Service Manual
The structure of this repair manual reflects the sequence of work steps for completely dismantling the
removed unit.
Tools required for carrying out the repair work are listed in the current text as well as in chapters “WS”
(List of Special Tools) and “WH” (Commercial Tools).
Important information on labor safety
As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully
responsible for labor safety.
The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding
any damage to persons and products during maintenance and repair work. Repair workshops must
familiarize themselves with these regulations prior to starting any work.
A suitably trained and skilled staff is required for a proper repair of these ZF products.
The repair workshop shall be responsible for the training.
The following safety references are used in this manual:
This symbol serves as a reference to special working procedures,

 CAUTION methods, information, use of auxiliaries etc... indicated in this
repair manual.
This symbol identifies situations in which lacking care may lead to

DANGER personal injury or damage to the product.
____________________________________________
NOTE: Thoroughly study this manual before starting any tests or repairs.
NOTE: Figures, drawings and parts in this manual do not always represent the original; they show
the working procedure.
Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on
size and weight (not even within one and the same illustration).
Carry out work according to the legend.
NOTE: After repair work and tests, the expert staff must verify that the product is perfectly
functioning again.
5871 529 002 0/3

Corporate Division
LABELING OF IDENTIFICATION PLATE
MIL-L-2105 D 05
LS/SAE 90
1 = Axle type
2 = Axle number
3 = ZF – parts list number
4 = Overall axle ratio/ version with or without ZF – multi-disk differential lock
5 = Oil grade
6 = Oil quality
Note on item 6: See ZF List of Lubricants for ZF axles TE - ML 05 !
INFORMATION ON SPARE PARTS ORDERING

The following information is required when ordering genuine ZF spare parts:
1. Axle type
2. Unit number
3. ZF – parts list number
4. Make and type of vehicle
5. Denomination of spare part
6. Spare parts number
7. Shipping mode
NOTE: Item 1, 2 and 3 are visible on the identification plate.
Please indicate all the a.m. details to avoid any mistakes in the delivery of the ordered spare parts!
5871 529 002 0/4

Corporate Division
Examples of contact patterns for the Gleason gear tooth system
Application: The examples of contact patterns are applicable for all bevel gear sets in MT and MS axles
which have a ratio between 1.5 < i < 6.
Also, the examples are only valid for ground bevel gear sets.
(The examples are only partly applicable for lapped contact patterns).
Ideal contact pattern:
Pinion shimming
h
Tooth root
- Convex
h Heel
Tooth top
+
2
Toe approx.  h
3
Tooth root
-
Concave
1
 h
Middle of tooth 2
Contact pattern setting:

The contact patterns are viewed on the crown wheel flanks.
The contact pattern must be tangent to the center of tooth flank (middle of tooth), otherwise it is too far on
the tooth top or on the tooth root.
The contact pattern should have a size of minimum 50% at the flank in h-direction (inspection criterion).
General:
By changing the pinion distance the contact pattern position is relocated in the direction of the tooth depth.
Shimming in + : = reduce pinion shim thickness (contact pattern moves to the top)
Shimming in - : = increase pinion shim thickness (contact pattern moves to the root)
Flank glossary:
Convex flank = Drive side
Concave flank = Coast side
Toe = Crown wheel inner side
Heel = Crown wheel outer side
Note:
The following pages (0.6 … 0.8) describe three different examples of contact patterns!
5871 529 002 0/5

Corporate Division
EXAMPLE 1: Dedendum tooth position
Contact pattern not o.k.

Convex
1
h
2
1
h
2
Concave
The contact pattern on the convex and concave flank is too far in the root, although more than 50% of the
flank in h-direction is covered.
An adjustment is necessary!
Feature: On the convex flank the contact pattern has an impression at the toe / root and on the
concave flank on the heel/root.
Adjustment: Add a smaller shim to the pinion!
Contact pattern o.k.
Convex
1
 h
2
Concave
1
 h
2
The contact pattern is in the flank without bridging and a minimum of 50% of the flank in h-direction is
covered.
The contact pattern in the example is relatively small. However, the contact pattern has an impression on the
middle of the tooth and would cover the flank optimally with a greater load (see sketch).
5871 529 002 0/6

Corporate Division
Example 2: Addendum tooth position
Convex
1
h
3
1
h
Concave 3
The contact pattern convex and concave is too far on the top. Also, the contact pattern is too small and is not
tangent to the flank middle line.
Adjustment: Use a thicker pinion spacer!
Convex
1
 h
2
Concave
1
 h
2
The convex contact pattern must be visible in the direction of the tooth center depth.
Min. 50% of the flank in direction of tooth depth is covered.
5871 529 002 0/7

Corporate Division
Example 3: “Line” contact pattern
Convex
1
ca.  h
3
1
ca.  h
3
Concave
The contact pattern convex and concave is too far up on the crown wheel. The contact pattern is also too
small and is not tangent to the flank middle line.
Adjustment: Add a thicker pinion spacer!
Convex
1
h
2
1
h
2
Concave
The convex contact pattern must have an impression at the tooth middle line.
A minimum of 50% of the tooth depth (flank) is covered.
Note:
An edge on the root of the tooth is allowed, this is
caused by the shot peening process (see example). Shot-peening edge
5871 529 002 0/8

Corporate Division
VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25.40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2.205 lb ( pounds )
9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per square inch lbf/in2 )
=
0.070 bar ( 0.071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0.264 Gallon ( Imp. )
4.456 Liter =
1 Gallon ( Imp. )
1 Liter =
0.220 Gallon ( US )
=
3.785 Liter 1 Gallon ( US )
=
1609.344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273.15 Kelvin
5871 529 002 0/9

Corporate Division
BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Densité linéaire en kg/m; Densité superficielle en t/m2
Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit New old Conversion Note
Unité Nouveau Vieux Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9,81 N
Force
Force
Arbeit A J (Joule) kpm 0,102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0,7355 KW
Power 1 KW = 1,36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9,81 Nm T (Nm) =
Torque (Newtonmeter) F (N) . r (m)
Couple
Kraftmoment M Nm kpm 1 kpm = 9,81 Nm M (Nm) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1,02 atü = 1,02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
5871 529 002 0/10

Corporate Division
TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148

Friction coefficient: µ tot.= 0.12 for screws and nuts without subsequent treatment, as well as for phosphated nuts.
Tighten manually!
Unless otherwise specified, the tightening torques can be taken from the following chart:
Metric ISO standard thread DIN 13, page 13

Dimension 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-fine thread DIN 13, page 13
Dimension 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
5871 529 002 0/11

Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223
Cons. Figure Designation Qty Chapter/Fig.

No. Order No.
Assembly truck 1/1

cpl. with tilting device 1/7
1 5870 350 000 1
Fixtures 1/1
2 5870 350 077 1
Clamping brackets 1/1
3 2
5870 350 075
Support 1/1
4 5870 350 125 1
Load carrying device 1/5

8/40
5 5870 281 043 1
5871 529 002 WS/1

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Fixture 1/7
6 5870 350 113 1
Inner extractor 1/11

8/24
MT-L 3085 II
7 1
5870 300 019
Eye bolt 1/11

8/24
MT-L 3085 II
8 1
5870 204 073
Inner extractor 1/11

8/24
9 1
5870 300 017
Eye nut 1/11

8/24
10 1
5870 204 076
5871 529 002 WS/2

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Rapid grip 1/12
11 1
5873 014 016
Basic tool 1/12

1/24
12 1
5873 004 001
Resetting device 1/22

1/23
13 5870 400 001 2
Rapid grip 1/24
14 5873 014 013 1
Load carrying device 3/1

6/19
6/24
15 5870 281 083 1
5871 529 002 WS/3

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Slotted nut wrench 3/6

6/11
6/25
16 5870 401 139 1 6/27
Clamping device 3/6

6/11
6/25
17 5870 240 002 1 6/27
Extractor 3/8
18 5870 000 065 1
Hexagon screw 3/8
19 AA00 331 360 2
Gripping device 3/9
20 AA00 684 425 1
5871 529 002 WS/4

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Basic tool 3/9
21 5873 002 000 1
Rapid grip 4/2

4/13
4/22
22 5873 012 016 1
Basic tool 4/2

4/13
4/22
23 5873 002 001 1
Grab sleeve 4/2
24 5873 003 029 1
Reduction 4/2
25 5873 003 011 1
5871 529 002 WS/5

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Pressure piece 4/2

4/3
5/15
26 5870 100 075 1 5/17
Locating pins 5/1

(M16x1,5) 5/9
5/20
27 5870 204 040 1 5/28
5/31
5/43
Pressure piece 5/13
5870 100 069

28 1
Load cell 5/13
29 5870 700 004 1
Lifting device 5/16
30 AA00 331 446 1
5871 529 002 WS/6

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Driver tool 6/4
31 5870 058 079 1
Handle 6/4
32 5870 260 004 1
Assembly fixture 6/6
33 5870 345 080 1
Measuring disk 6/16

D / DL 2400 2
DHL 2400 1
34 AA00 848 434
Measuring disk 6/16

DHL 2400
35 AA00 848 397 1
5871 529 002 WS/7

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Measuring support 6/16
36 AA00 860 154 2
Straightedge
6/16
8/32
37 5870 200 022 1 8/35
Adjusting screws 6/21

(M20) 7/2
38 5870 204 024 1
Driver tool 6/26
39 5870 048 233 1
Assembly fixture 8/1
40 5870 610 010 1
5871 529 002 WS/8

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Insert 8/1
(M22x1,5)
41 5870 610 002 1
Pressure ring 8/7
42 5870 506 172 1
Driver tool 8/8
43 5870 051 065 1
Fixing device 8/14
44 AA00 680 530 1
Measuring disk 8/25
45 AA00 360 730 1
5871 529 002 WS/9

Corporate Division
and Axle Systems
MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223

No. Order No.
Adjusting screws 8/40

(M18x1,5)
46 5870 204 029 1
HP pump 8/42
8/43
47 5870 287 007 1
Clutch 8/42
48 0501 207 939 1
Reduction 8/42
(M18x1,5)
49 5870 950 161 1
Breather bottle 8/42
50 5870 286 072 1
5871 529 002 WS/10

Corporate Division
and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure Designation Qty. Chapter/Fig .
No. Order no.
Magnetic stand
5870 200 055

1 1 Universal
Dial indicator
5870 200 057

2 1 Universal
Gauge blocks
5870 200 066 70 mm

3 1 Universal
5870 200 067 100 mm
Digital depth gauge
5870 200 072 200 mm

4 1 Universal
5870 200 114 300 mm
Digital caliper gauge
5870 200 109 150 mm

5 1 Universal
5871 529 002 WH/1

Corporate Division
and Axle Systems
No. Order no.
Torque wrench
5870 203 030 0.6 -6.0 Nm
5870 203 031 1.0 – 12 Nm
5870 203 032 3.0 – 23 Nm

6 1 Universal
5870 203 033 5.0 – 45 Nm
5870 203 034 10 – 90 Nm
5870 203 039 80 – 400 Nm
5870 203 016 140 – 750 Nm
5870 203 011 750 - 2000 Nm
Hot air blower
5870 221 500 230 V

7 1 Universal
5870 221 501 115 V
Plastic hammer
5870 280 004 Ø 60 mm

8 1 Universal
Substitute nylon insert
5870 280 006
Lifting strap
5870 281 026

9 1 Universal
5871 529 002 WH/2

Corporate Division
and Axle Systems
No. Order no.
Lifting chain
5870 281 047

10 1 Universal
Pry bar
5870 345 071

11 1 Universal
Striker
5870 650 004

12 1 Universal
Set of internal pliers

I1-I2-I3-I4
13 5870 900 013 1 Universal
Set of internal pliers

I11-I21-I31-I41 90°
14 5870 900 014 1 Universal
5871 529 002 WH/3

Corporate Division
and Axle Systems
No. Order no.
Set of external pliers

A1-A2-A3-A4
15 5870 900 015 1 Universal
Set of external pliers

A01-A02-A03-A04 90°
16 5870 900 016 1 Universal
Two-armed puller
5870 970 001

Jaw width 80 mm
Throat depth 100 mm
5870 970 002
Jaw width 120 mm
Throat depth 125 mm
5870 970 003
Jaw width 170 mm
Throat depth 125 mm
5870 970 004
17 Jaw width 200 mm 1 Universal
Throat depth 175 mm
5870 970 006
Jaw width 350 mm
Throat depth 250 mm
5870 970 007
Jaw width 520 mm
Throat depth 300 - 500 mm
5870 970 026
Jaw width 250 mm
Throat depth 200 mm
5870 970 028
Jaw width 380 mm
Throat depth 200 mm
5871 529 002 WH/4

Corporate Division
and Axle Systems
No. Order no.
Three armed puller
5870 971 001

Jaw width 85 mm
Throat depth 65 mm
5870 971 002
Jaw width 130 mm
Throat depth 105 mm
5870 971 003
Jaw width 230 mm
18 Throat depth 150 mm 1 Universal
5870 971 004
Jaw width 295 mm
Throat depth 235 mm
5870 971 005
Jaw width 390 mm
Throat depth 270 mm
5870 971 006
Jaw width 640 mm
Throat depth 300 mm
5871 529 002 WH/5

Corporate Division
and Axle Systems
ZF – MULTITRAC AXLE
MT-L 3085 II / MT-L 3095 II
1. Disassembly output and brake
Fix axle to assembly truck.
(S) Assembly truck 5870 350 000

(S) Fixtures 5870 350 077
(S) Clamping brackets 5870 350 075
(S) Support 5870 350 125
Figure 1
Before clamping the axle fully turn in the support (S)!
Position axle first onto the two fixtures (S), secure with
clamping brackets (S) and then unbolt the support (S) until
contact with the axle is obtained!
Loosen screw plugs (3x, see Figure 2 and 3) and drain oil from
the axle.
Figure 2
Figure 3
5871 529 002 1/1

Corporate Division
and Axle Systems
Remove the breather valve (see arrow).
To avoid any damage, the breather valve must be removed

when separating the output!
Figure 4
Secure the output with the lifting device (S) and loosen hexagon
screws.
Then separate the output assy from the axle housing.
(S) Load carrying device 5870 281 043
Fix the load carrying device (S) with a wheel nut!
Figure 5
Pull stub shaft and sun gear shaft.
Pay attention to potentially releasing shim(s)!
Figure 6
Fix output to assembly truck.
(S) Assembly truck 5870 350 000

(S) Fixture 5870 350 113
Figure 7
5871 529 002 1/2

Corporate Division
and Axle Systems
Use a lever to remove the cover from the output shaft.
Figure 8
Loosen locking screws and remove the releasing cover.
Figure 9
Press planetary carrier with a two-armed puller out of the profile

of the output shaft.
Figure 10
Lift the planetary carrier out of the brake housing by means of

the lifting device.
MT-L 3085 (planetary carrier with 3 planetary gears)

(S) Inner extractor 5870 300 019
(S) Eye bolt 5870 204 073

(S) Eye nut 5870 204 076
Figure 11
5871 529 002 1/3

Corporate Division
and Axle Systems
Pull the tapered roller bearing from the planetary carrier.
(S) Rapid grip 5873 014 016

(S) Basic tool 5873 004 001
Figure 12
Disengage retaining ring.
Figure 13
Pull off planetary gear.
Figure 14
Lift the end plate out of the brake housing.
Figure 15
5871 529 002 1/4

Corporate Division
and Axle Systems
Lift the disk package out of the brake housing.
Figure 16
Loosen hexagon screws, remove releasing cover and cup spring.
Figure 17
Mount breather valve and press piston out of the brake housing
by means of compressed air.
Figure 18
If necessary, remove guide ring, back-up rings and grooved rings

out of the annular grooves of the brake housing (see arrows).
For the installation position of the single parts please also

refer to the following sketch!
Figure 19
5871 529 002 1/5

Corporate Division
and Axle Systems
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring
6 = Back-up ring
7 = Slide ring seal
8 = Output shaft
Figure 20
Lift the brake housing from the output shaft by means of the
lifting device.
Figure 21
Version with slide ring seal

Use a lever to remove the slide ring seal from the brake housing.
Version with combi seal

Use a lever to remove the shaft seal from the brake housing.
If necessary, force out both bearing outer rings.
(S) Resetting device 5870 400 001
Figure 22
5871 529 002 1/6

Corporate Division
and Axle Systems
Version with slide ring seal

Use a lever to remove the slide ring seal from the output shaft.
Version with combi seal

Visually check the screening plate regarding wear marks, and if
required, separate it from the output shaft.
(S) Resetting device 5870 400 001
Figure 23
Pull the tapered roller bearing from the output shaft.
(S) Rapid grip 5873 014 013

(S) Basic tool 5873 004 001
Figure 24
5871 529 002 1/7

Corporate Division
and Axle Systems
2. Disassembly axle housing
Secure axle housing with the lifting device and loosen the
hexagon screws.
Then separate the axle housing from the axle drive housing.
Pay attention to releasing differential!
Figure 1
Loosen the threaded connections and remove the releasing brake

tube.
Figure 2
Loosen screw neck.
Figure 3
Pull the bearing outer ring out of the bearing hole and remove the
shim behind.
Then remove the O-ring (see arrow).
Figure 4
5871 529 002 2/1

Corporate Division
and Axle Systems
3. Disassembly input
Use the lifting device to lift the differential out of the axle drive
housing.
(S) Load carrying fixture 5870 281 083
Disassembly of the differential is described as of page 4/1!
Figure 1
Pull the bearing outer ring (see arrow) out of the housing hole
and remove the shim behind.
Figure 2
Press piston (see arrow) out of the axle housing (see subsequent
Figure) by means of compressed air.
This operation is only necessary for the version with DHL!
Figure 3
Figure 4
5871 529 002 3/1

Corporate Division
and Axle Systems
Heat slotted nut by means of hot air blower.
Slotted nut is secured with Loctite (Type no.: 262)!
Figure 5
Loosen slotted nut and remove the shim behind.
(S) Slotted nut wrench 5870 401 139

(S) Clamping device 5870 240 002
Figure 6
Pull the input flange from the input pinion and use a lever to
remove the shaft seal behind from the axle drive housing.
Figure 7
Press input pinion from the axle drive housing and remove the
releasing tapered roller bearing.
(S) Extractor 5870 000 065

(S) Hexagon screw (2x) AA00 331 360
Figure 8
5871 529 002 3/2

Corporate Division
and Axle Systems
Remove spacer ring and pull the tapered roller bearing from the
input pinion.
(S) Gripping device AA00 684 425

(S) Basic tool 5873 002 000
Figure 9
If necessary, force both bearing outer rings out of the axle drive
housing.
Figure 10
5871 529 002 3/3

Corporate Division
and Axle Systems
4. Disassembly differentials
4.1 Disassembly multi-disk differential lock DHL-2400
Remove axial roller cage (arrow).
Figure 1
Pull both tapered roller bearings from the differential.
Crown wheel side

(S) Grab sleeve 5873 012 016
(S) Basic tool 5873 002 001
Opposite side
(S) Grab sleeve 5873 003 029
(S) Basic tool 5873 002 001
(S) Reduction 5873 003 011
(S) Pressure piece 5870 100 075
Figure 2
Preload the differential by means of the press, loosen the

hexagon screws and remove the releasing housing cover.
Figure 3
Preload the housing cover/compression spring by means of the

press and disengage the retaining ring.
Then remove sliding sleeve and compression spring from the

housing cover.
Figure 4
5871 529 002 4/1

Corporate Division
and Axle Systems
Remove single parts.

2 3
1
4 1 = Pressure piece
2 = Cage
5
3 = Lever (12x)
4 = Disk carrier
5 = Disk package
Figure 5
Preload differential by means of the press, loosen locking screws

and housing cover.
Figure 6
Remove axle bevel gear with thrust washers from the differential
housing.
Figure 7
Force out both slotted pins.
Figure 8
5871 529 002 4/2

Corporate Division
and Axle Systems
Force out both differential axles (short) and remove the releasing
spider gears with thrust washers from the differential housing.
Figure 9
Pull the differential axle (long) and remove the releasing spider
gears with thrust washers from the differential housing.
Figure 10
Remove the axle bevel gear and the shim behind.
Figure 11
Press crown wheel from the differential carrier.
Figure 12
5871 529 002 4/3

Corporate Division
and Axle Systems
4.2 Disassembly differential D-2400
(S) Grab sleeve 5873 012 016

(S) Basic tool 5873 002 001
Figure 13
Preload the differential by means of the press, loosen the

hexagon screws and remove the releasing housing cover.
Figure 14
Preload the differential by means of the press, loosen locking

screws and housing cover.
Figure 15
Remove axle bevel gear with thrust washers from the differential
housing.
Figure 16
5871 529 002 4/4

Corporate Division
and Axle Systems
Force out both slotted pins.
Figure 17
Force out both differential axles (short) and remove the releasing
spider gears with thrust washers from the differential housing.
Figure 18
Pull the differential axle (long) and remove the releasing spider
gears with thrust washers from the differential housing.
Figure 19
Remove the axle bevel gear and the shim behind.
Figure 20
5871 529 002 4/5

Corporate Division
and Axle Systems
Figure 21
5871 529 002 4/6

Corporate Division
and Axle Systems
4.3 Disassembly multi-disk differential lock DL-2400
(S) Grab sleeve 5873 012 016

(S) Basic tool 5873 002 001
Figure 22
Preload the differential by means of the press, loosen locking

screws and housing cover.
Figure 23
Lift the axle bevel gear with pressure ring, disk package and
thrust washers out of the differential housing.
Figure 24
Remove spider shafts and axle bevel gears (see Figure) out of the
differential housing.
Figure 25
5871 529 002 4/7

Corporate Division
and Axle Systems
Remove the second axle bevel gear.
Figure 26
Lift the pressure ring out of the differential housing and remove
the disk package and thrust washers behind.
Figure 27
Figure 28
5871 529 002 4/8

Corporate Division
and Axle Systems
5. Reassembly differentials
5.1 Reassembly multi-disk differential lock DHL-2400
Mount two locating pins (S) and press the heated crown wheel
onto the differential housing until contact is obtained.
(S) Locating pins 5870 204 040
Figure 1
Insert thrust washer into the differential housing.
Figure 2
Insert axle bevel gear.
Figure 3
Insert spider gears with thrust washers into the differential

housing and fix them with the spider shaft (long).
Thrust washers must be positioned with the tabs (see arrow)

being located in the recesses of the differential housing!
Figure 4
5871 529 002 5/1

Corporate Division
and Axle Systems

housing and fix them with the two spider shafts (short).
1 2
Thrust washers must be positioned with the tabs (see arrow
1) being located in the recesses of the differential housing!
Pay attention to radial installation position of the spider

shafts (fixing holes, arrow 2)!
Figure 5
Fix spider shafts (short) with slotted pins.
Flush mount slotted pins!
Figure 6
Mount second axle bevel gear.
Figure 7
Fix the thrust washers into the housing cover by means of grease.
Figure 8
5871 529 002 5/2

Corporate Division
and Axle Systems
Mount two adjusting screws (S) and insert the housing cover
until contact with the differential housing is obtained.
Preload the differential by means of the press and bolt with new
locking screws.
Tightening torque (M16/12.9) MA = 400 Nm
Figure 9
Install compression spring onto the sliding sleeve.
Figure 10
Insert the premounted sliding sleeve into the housing cover.
Preload the compression spring by means of the press and

engage the retaining ring into the annular groove of the sliding
sleeve.
Figure 11 Setting of disk package
Premount single parts according to the adjacent sketch.

9 1 = Housing cover
8 5 2 = Pressure piece
7 3 = Cage
6 4 = Lever (12x)
4 5 = Disk carrier
6 = Pressure ring
3
7 = Inner disks
2
8 = Outer disks (optional)
1 9 = Snap ring
Figure 12
For the number of disks and the disk arrangement please
refer to the relating spare parts list!
5871 529 002 5/3

Corporate Division
and Axle Systems
Preload disk package with an axial force of F = 50 +30 KN.
Then check the setting dimension „A“ = 1.05 ±0.1 mm from

the collar of the differential cover to the plane face of the outer
disk (see also below sketch) .

(S) Load cell 5870 700 004
Any deviation from the specified setting dimension must be

corrected with a corresponding outer disk!!
Figure 13
A Legend to sketch:
A = Setting dimension = 1.05 ±0.1 mm

B = Contact face
To obtain a correct measuring result:

The housing cover may only be supported on the contact face
B (B)!
Ensure that the assembly fixture (S) is only supported on the disk
package and not on the disk carrier (5)!
Figure 14
Position housing cover onto pressure piece (S, see arrow).
Insert two hexagon screws into the housing cover to radially fix
the disk package.
Figure 15
Position the premounted differential with the lifting device (S)

onto the housing cover and preliminarily fix with hexagon
screws.
(S) Lifting device AA00 331 446
Figure 16
5871 529 002 5/4

Corporate Division
and Axle Systems
Preload the differential by means of the press and the pressure

piece (S).
Then finally tighten the housing cover with hexagon screws.
Figure 17
Heat both tapered roller bearings and insert until contact is

obtained.
Adjust tapered roller bearing after cooling down!
Figure 18
Fix axial roller cage (see arrow) to the sliding sleeve by means of
grease.
Figure 19
5871 529 002 5/5

Corporate Division
and Axle Systems
5.2 Reassembly differential D-2400
Figure 20
Figure 21
Insert axle bevel gear.
Figure 22

housing and fix them with the spider shaft (long).
Thrust washers must be positioned with the tabs (see arrow)

being located in the recesses of the differential housing!
Figure 23
5871 529 002 5/6

Corporate Division
and Axle Systems

housing and fix them with the two spider shafts (short).
1 2
Thrust washers must be positioned with the tabs (see arrow
1) being located in the recesses of the differential housing!
Pay attention to radial installation position of the spider

shafts (fixing holes, arrow 2)!
Figure 24
Fix spider shafts (short) with slotted pins.
Flush mount slotted pins!
Figure 25
Figure 26
Figure 27
5871 529 002 5/7

Corporate Division
and Axle Systems
locking screws.
Figure 28
Attach the housing cover and preload the differential with the
press.
Then fix the housing cover with hexagon screws.
Figure 29

obtained.
Figure 30
5871 529 002 5/8

Corporate Division
and Axle Systems
5.3 Reassembly multi-disk differential lock DL-2400
Figure 31
Figure 32
Mount outer and inner disks in alternating order, starting with an

outer disk.
The installation clearance of the internal parts is corrected

by mounting outer disks with different thicknesses!
The difference in thickness between the left and the right

disk package must only be 0.1 mm at maximum!
Figure 33
Place the pressure ring.
Figure 34
5871 529 002 5/9

Corporate Division
and Axle Systems
Insert the axle bevel gear until contact is obtained and install the
inner disks with the teeth.
Figure 35
Preassemble the differential spider and insert it into the

differential housing /into the pressure ring.
Figure 36
Figure 37
Zweiten Druckring in das Differentialgehäuse einsetzen.
Figure 38
5871 529 002 5/10

Corporate Division
and Axle Systems
Mount outer and inner disks in alternating order, starting with an

inner disk.
The installation clearance of the internal parts is corrected

by mounting outer disks with different thicknesses!
The difference in thickness between the left and the right

Figure 39
Determine the installation clearance 0.2 … 0.7 mm
Measure dimension I, from the mounting face of the differential

housing to the plane face of the outer disk.
Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 44.30 mm
Figure 40
Measure dimension II, from the contact face of the outer disk to
the mounting face on the housing cover.
Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . 43.95 mm
CALCULATION EXAMPLE:
Dimension I . . . . . . . . . . . . . . . . . . . . . . . . . . 44.30 mm
Dimension II . . . . . . . . . . . . . . . . . . . . . . . . . . - 43.95 mm
Difference = disk clearance = 0.35 mm
Figure 41
Any deviation from the required installation clearance is to

be corrected with corresponding outer disks (s = 2.7, s = 2.9,
s = 3.0, s = 3.1, s = 3.2, s = 3.3 or s = 3.5 mm), taking care
that the difference in thickness between the left and the right
5871 529 002 5/11

Corporate Division
and Axle Systems
Bild 42
locking screws.
Bild 43

obtained.
Bild 44
5871 529 002 5/12

Corporate Division
and Axle Systems
6. Reassembly input
 Ifbecrown wheel or input pinion are damaged, both parts must

jointly replaced!
6.1 Determination of shim thickness to obtain a correct

contact pattern
 The following measuring procedures must be carried out

with utmost accuracy!
Inaccurate measurements lead to an incorrect contact
pattern requiring an additional disassembly and reassembly
of input pinion and differential!
Read dimension I from the axle drive housing.
221,10 Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 221.10 mm
Figure 1
Read dimension II (pinion dimension).
181,0 ± 0 Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 181.00 mm
Figure 2
5871 529 002 6/1

Corporate Division
and Axle Systems
Determine dimension III (bearing width).
Dimension III e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 39.10 mm
CALCULATION EXAMPLE „A“:

Dimension I. . . . . . . . . . . . . . . . . . . . . . . 221.10 mm
Dimension II . . . . . . . . . . . . . . . . . . . . . . - 181.00 mm
Dimension III . . . . . . . . . . . . . . . . . . . . . . - 39.10 mm
Difference = shim s = 1.00 mm
Figure 3
6.2 Reassembly of input pinion
Undercool the external bearing outer ring and insert it into the
axle drive housing until contact is obtained.
(S) Driver tool 5870 058 079

(S) Handle 5870 260 004
Figure 4
Insert the determined shim e.g. s = 1.00 mm into the housing

hole.
Figure 5
Undercool the internal bearing outer ring and bring it into contact
position in the housing hole by using the assembly fixture (S).
(S) Assembly fixture 5870 345 080
Figure 6
5871 529 002 6/2

Corporate Division
and Axle Systems
Heat the tapered roller bearing and insert it into the input pinion
until contact is obtained.
Figure 7
Setting of rolling torque of input pinion bearing 1.5 ... 4.0 Nm

(without shaft seal)
Insert spacer (e.g. s = 8.18 mm).
 According to our experience the necessary rolling torque is

obtained when reusing the spacer which has been removed
during disassembly (e.g. s = 8.18 mm)!
A later check of the rolling torque, however, is absolutely
necessary!
Figure 8
Insert the preassembled input pinion into the axle drive housing
and insert the heated tapered roller bearing until contact is
obtained.
Figure 9
Press the protection plate onto the input flange (see arrow) until
contact is obtained.
 Dochecked!
not fit the shaft seal until the contact pattern has been
Figure 10
5871 529 002 6/3

Corporate Division
and Axle Systems
Insert input flange and fix it by means of disk and slotted nut.
Tightening torque MA = 1200 Nm

 Preliminarily mount slotted nut without Loctite!

While tightening rotate the input pinion several times in both
directions!
Figure 11
Check rolling torque (1.5 ... 4.0 Nm without shaft seal).
 When installing new bearings try to achieve the upper value

of the rolling torque!
In case of deviations from the necessary rolling torque

correct with a corresponding spacer (Figure 8, page 6/3) as
specified below!
Insufficient rolling torque install thinner spacer ring
Excessive rolling torque install thicker spacer ring!
Figure 12
Grease O-rings (2x, see arrows) and insert them into the annular
grooves of the piston.
 DHL!
Operation Figure 13 and 14 is only necessary for version with
Figure 13
Insert piston (see arrow) into the bearing housing until contact is
obtained.
Figure 14
5871 529 002 6/4

Corporate Division
and Axle Systems
6.3 Determination of shims for setting of bearing rolling

torque (differential housing) and backlash (bevel
gear set)
 Required shims must be determined by means of the crown

wheel deviation read (deviation/test dimension), the deviation
of the block gauge and the corresponding data in the
following tables!
Read crown wheel deviation.

101 +/- 0 The test dimension „101“ is stamped into the crown wheel
Figure 15 rear side. If no – or + deviation is indicated, this value
corresponds to the actual value ”0” in the table below.
Any – or + deviation of the test dimension caused by
production is also marked on the crown wheel rear side
(e.g. - 10 or - 20 or 10).
Determine deviation of block gauge „C“.

D / DL 2400 HK Block gauge = 361 mm
DHL 2400 HK Block gauge = 390.33 mm
Insert bearing outer ring into the measuring disc (S, arrow 1).
(S) Measuring disc AA00 848 434
Place differential into the bearing outer ring and put on the upper
bearing outer ring.
Position the differential exactly by turning the differential

and the upper bearing outer ring in both directions several
times (rolling-in).
Put on the measuring disc (S, arrow 2) and determine the

deviation of block gauge „C“.
(S) Measuring disc (D / DL 2400) AA00 848 434

(S) Measuring disc (DHL 2400) AA00 848 397
(S) Measuring support AA00 860 154
(S) Straightedge 5870 200 022
Figure 16
C Legend to sketch:
C = Block gauge D / DL 2400 HK = 361 mm
DHL 2400 HK = 390.33 mm
1 = Axle housing
1 3 2 = Shim (crown wheel side)
3 = Shim (diff. carrier side)
4 = Axle housing
2
4
Figure 17
5871 529 002 6/5

Corporate Division
and Axle Systems
Crown wheel Shim table D / DL 2400 HK - Block gauge: 361 mm
Crown wheel
Crown wheel
(Crown wheel
(Crown wheel
(Crown wheel
Dimension C
Dimension C
Dimension C
(Diff. carrier
(Diff. carrier
(Diff. carrier
Deviation
Deviation
Deviation
Shim A
Shim B
Shim A
Shim B
Shim A
Shim B
side)
side)
side)
side)
side)
side)
-0.20 1.40 0.80 -0.20 1.30 0.70 -0.20 1.20 0.60
-19 1 21
-0.10 1.30 0.90 -0.10 1.20 0.80 -0.10 1.10 0.70
to to to
0.00 1.20 1.00 0.00 1.10 0.90 0.00 1.00 0.80
-10 10 30
0.10 1.10 1.10 0.10 1.00 1.00 0.10 0.90 0.90
-0.20 1.40 0.70 -0.20 1.30 0.60
-9 11
-0.10 1.30 0.80 -0.10 1.20 0.70
to to
0.00 1.20 0.90 0.00 1.10 0.80
0 20
0.10 1.10 1.00 0.10 1.00 0.90
Shim table DHL 2400 HK - Block gauge: 390.33 mm

Crown wheel
Crown wheel
Crown wheel
(Crown wheel
(Crown wheel
(Crown wheel
Dimension C
Dimension C
Dimension C
(Diff. carrier
(Diff. carrier
(Diff. carrier
Deviation
Deviation
Deviation
Shim A
Shim B
Shim A
Shim B
Shim A
Shim B
side)
side)
side)
side)
side)
side)
-0.20 1.40 0.80 -0.20 1.30 0.70 -0.20 1.20 0.60
-25 -5 15
-0.10 1.30 0.90 -0.10 1.20 0.80 -0.10 1.10 0.70
to to to
0.00 1.20 1.00 0.00 1.10 0.90 0.00 1.00 0.80
-16 4 24
0.10 1.10 1.10 0.10 1.00 1.00 0.10 0.90 0.90
-0.20 1.30 0.80 -0.20 1.20 0.70
-15 5
-0.10 1.20 0.90 -0.10 1.10 0.80
to to
0.00 1.10 1.00 0.00 1.00 0.90
-6 14
0.10 1.00 1.10 0.10 0.90 1.00
5871 529 002 6/6

Corporate Division
and Axle Systems
Insert the determined shim (e.g. s = 0.9 mm) into the hole of the
axle housing and adjust the bearing outer ring (see arrow) until
Figure 18
Cover some drive and coast flanks of the crown wheel with
marking ink.
Then insert the premounted differential into the axle drive

housing.
Figure 19
Insert the determined shim (e.g. s = 1.1 mm) into the hole of the
axle housing and adjust the bearing outer ring (see arrow) until
Figure 20
Mount two locating pins (S) and bring the axle housing into
contact position with the axle drive housing by means of the
lifting device.
Then preliminarily fix the axle housing with 4 hexagon screws.
Figure 21  Preliminarily mount the axle housing without O-ring!
5871 529 002 6/7

Corporate Division
and Axle Systems
Leakage test of lock
Pressurize the lock (p = 1 bar), close shut-off valve and remove

air line.
No noticeable pressure loss is allowed to occur within 10 sec!
 This operation is only necessary for version with DHL!

Figure 22
By rotating the input flange, roll crown wheel over the input
pinion in both directions several times.
Then remove the axle housing again and lift the differential out
of the axle drive housing.
Compare the obtained contact pattern with contact pattern

examples Page 0/5 … 0/8.
In case of any contact pattern deviation, a measuring error

was made when determining the shim (Figure 5, page 6/2),
which must be corrected by all means!
Figure 23
After the contact pattern check insert the differential again into
the axle drive housing.
Figure 24
Reassembly of shaft seal (Figure 25 … 27)
Loosen the slotted nut and pull the input flange from the input
pinion.

Figure 25
5871 529 002 6/8

Corporate Division
and Axle Systems
Mount the shaft seal with the seal lip showing to the oil chamber.
(S) Driver tool 5870 048 233
 The exact installation position of the shaft seal is obtained

when using the specified driver tool (S)!
Wet the outer diameter of the shaft seal with spirit directly
before installation and fill the space between seal and dust lip
with grease!
Figure 26
Insert input flange and finally tighten by means of disk and

slotted nut.

Cover the thread of the slotted nut with Loctite (Type no.:
262)!
Figure 27
5871 529 002 6/9

Corporate Division
and Axle Systems
7. Reassembly axle housing
Grease O-ring (see arrow) and insert it into the axle housing.
Figure 1
Mount two locating pins (S) and bring the axle housing into
contact position with the axle drive housing by using the lifting
device.
Then fix the axle housing by means of hexagon screws.
After assembling the axle housing secure the axle with

clamping brackets (S)!)
Figure 2
Mount fitting.
Figure 3
Grease O-ring and insert it into the annular groove of the brake
tube (see arrow).
Figure 4
5871 529 002 7/1

Corporate Division
and Axle Systems
Mount brake tube with threaded connection and hexagon nut (see
arrow).
Figure 5
Provide screw plug with a new O-ring and fit it.
Figure 6
5871 529 002 7/2

Corporate Division
and Axle Systems
8. Reassembly output and brake
Pull in wheel stud into the output shaft until contact is obtained.
(S) Wheel stud puller - basic tool 5870 610 010

(S) Insert (M22x1.5) 5870 610 002
 Special tool (S) may only be used for repair solution when
exchanging individual wheel studs with mounted output
shaft! When using a new output shaft, mount the wheel studs
with the press.
Figure 1
Heat tapered roller bearing and insert it into the output shaft until
Figure 2
Version with slide ring seal Figure 3 … 4
Wet O-ring of slide ring seal and locating hole with spirit.
Snap new slide ring seal (part 1) into the output shaft.
Then mount new slide ring seal (part 2) accordingly into the
brake housing.
 For the installation position of the seal please also refer to

sketch 12, page 8/4!
Figure 3
The surface of the slide ring seal may not have any grooves,
scratches or other types of damage!
Take care that the sealing surface is parallel to the housing
face!
The O-rings must be mounted evenly into the locating hole
and must not bulge out of the hole!
Risk of injury - Metal rings have extremely sharp edges!
Wear protective gloves!
Figure 4
5871 529 002 8/1

Corporate Division
and Axle Systems
Insert both bearing outer rings (see arrows) into the brake
housing until contact is obtained.
Figure 5
Version with combi seal Figure 6 … 8

1 2
The adjacent sketch shows the installation position of the combi
seal.
3
1 = Output shaft
2 = Brake housing
3 = Combi seal consisting of: a = Shaft seal
a b = Screening plate
b
Figure 6
Heat slide bushing and position it at the collar of the output shaft.
Then position slide bushing with a pressure ring (S).
(S) Pressure ring 5870 506 172
 The exact installation position is obtained when using the

specified pressure ring (S)!
Figure 7
Insert shaft seal into the brake housing.
(S) Driver tool 5870 051 065
 The exact installation position is obtained when using the

specified driver tool (S)!
Pay attention to installation position (see also Figure 6)!

Wet the outer diameter of the shaft seal with spirit right
before the assembly!
Figure 8
5871 529 002 8/2

Corporate Division
and Axle Systems
Insert the premounted brake housing by means of the lifting

device over the output shaft until contact is obtained.
Before clamping the seal rings (slide ring seal) to installation

dimension, clean the sliding surfaces and apply an oil film.
We recommend to use a leather cloth soaked with oil!
Figure 9
Insert back-up rings and grooved rings into the annular grooves
of the brake housing (see arrows).
 Pay attention to the installation position; please also refer to

sketch 12, page 8/4!
Figure 10
Clean the annular groove of the brake housing with spirit.
Then insert the guide ring into the annular groove (see also the
following sketch) and fix it with Loctite (type no.: 415) at its
extremities (see arrows).
 The full circumference of the guide ring must be in an exact

contact position!
Upon installation the orifice of the guide ring must show

upwards (12 o’clock)!
Figure 11
5871 529 002 8/3

Corporate Division
and Axle Systems
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring
6 = Back-up ring
7 = Slide ring seal
8 = Output shaft
Figure 12
Flush-mount the slotted pins (6x) into the holes of the piston.
Figure 13
Insert the piston into the brake housing and carefully install with
the fixing device (S) until contact is obtained.
(S) Fixing device AA00 680 530
 Sufficiently oil seal surface of piston/back-up rings, grooved

rings and guide ring (W-10 oils to be used)!
Figure 14
5871 529 002 8/4

Corporate Division
and Axle Systems
Insert disk and cup spring with the convex side showing upwards
into the piston.
Figure 15
Insert cover and fix it by means of hexagon screws.
Figure 16
Mount outer and inner disks.
 For the number of disks and the disk arrangement please

refer to the relating spare parts list!
Figure 17
Insert end plate.
Figure 18
5871 529 002 8/5

Corporate Division
and Axle Systems
Press stop bolt into the planetary carrier until contact is obtained.
1
Legend to sketch:
1 = Stop bolt
2 = Planetary carrier
2
Figure 19
Illustration shows single parts of planetary gear.

1
2 1 = Cylindrical roller bearing
2 = Packaging sleeve
3 3 = Snap ring
4 4 = Planetary gear
 Planetary gear can only be supplied as component with

premounted cylindrical roller bearing!
Figure 20
Heat bearing inner rings and insert the premounted planetary

gears with large radius facing the planetary carrier (downwards)
 Adjust bearing inner rings after cooling down!

Then fix planetary gears by means of retaining rings.
Figure 21
Heat tapered roller bearing and install it to the planetary carrier

Figure 22
5871 529 002 8/6

Corporate Division
and Axle Systems
Wet front face (contact face bearing inner ring, arrow 1) and
profile (teeth, arrow 2) in the output shaft with anti-corrosive
agent Weicon Anti Size (ZF-order no.: 0671 196 001).
1
2 Use 18 gr Weicon Anti Size on each output side!
Figure 23
Align disk package centrally and radially.
Then insert the planetary carrier by means of the lifting device

into the teeth of the output shaft.

(S) Eye bolt 5870 204 073

Figure 24 (S) Eye nut 5870 204 076
Setting of gap width output shaft / planetary carrier
Bring planetary carrier with measuring disk (S) and three old
locking screws, which were removed during disassembly, into
contact position.
(S) Measuring disk AA00 360 730
Figure 25
Pivot output 180° and measure gap width from the output shaft
to the planetary carrier (see also subsequent sketch).
Gap width e.g. . . . . . . . . . . . . . . . . . . . . . . 0.21 mm
Then remove the locking screws and the measuring disk again.
Figure 26
5871 529 002 8/7

Corporate Division
and Axle Systems
Legend to sketch:
1 = Planetary carrier
1 2 = Output shaft
X
2 X = Gap width
Figure 27
Select the cover (optional) on the basis of the following table.
Determined gap Offset to be used on ZF-Order no.

width (Delta) the cover
0.30 … 0.20 mm 0.13 ±0.01 mm 4474 353 172
0.199 … 0.14 mm 0.07 ±0.01 mm 4474 353 172
0.139 … 0.02 mm 0.0 mm 4474 353 115
 Cover 4474 353 172 has an offset of 0.07 mm on one side and
an offset of 0.13 mm on the other side!
Offset 0.13 mm is visually marked with an annular groove

Figure 28 (see arrow)!
Insert the cover with the offset e.g. 0.07 mm showing to the
planetary carrier and tighten with new locking screws.
 When using the cover with offset 0.07 mm, the groove
(Figure 28) must be visible when the cover is installed!
Tighten locking screws successively with a tightening torque

of 200 Nm!
Then retighten the locking screws successively with a
tightening torque of 500 Nm!
Figure 29
Install O-ring (see arrow 1) to the cover.
Then wet contact face (arrow 2) with Terostat MS 9360 (ZF-

order no.: 0666 690 171)!
2
 Use new cover and O-ring!

1 Pay attention to curing period Terostat > 24 hours!
Figure 30
5871 529 002 8/8

Corporate Division
and Axle Systems
Insert the cover into the output shaft until contact is obtained.
Figure 31
Set the axial play of the sun gear shaft 0.5 ... 2.0 mm
Determine dimension I, from the mounting face of the brake

housing to the front face of the stop bolt.
Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 19.75 mm
(S) Gauge blocks 5870 200 066

Figure 32
Insert stub shaft into the teeth of the axle bevel gear until contact
is obtained.
Pay attention to the installation position; mount the stub

shaft with the long teeth showing to the differential!
Bild 33
Insert the sun gear shaft until contact is obtained.
Figure 34
5871 529 002 8/9

Corporate Division
and Axle Systems
Measure dimension II, from the front face of the sun gear shaft to
the mounting surface of the axle housing.
Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 17.15 mm
Figure 35
CALCULATION EXAMPLE:
Dimension I . . . . . . . . . . . . . . . . . . . . . . . . . . 19.75 mm
Dimension II . . . . . . . . . . . . . . . . . . . . . . . . . . - 17.15 mm
Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 mm
Required axial play e.g. . . . . . . . . . . . . . . . . . - 1.00 mm
Difference = shim e.g. s = 1.60 mm
Insert sun gear shaft into the planetary carrier.
Figure 36
Fix determined shim(s) e.g. s = 1.60 mm with grease into the

sun gear shaft.
Figure 37
5871 529 002 8/10

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and Axle Systems
Fix O-ring (see arrow) with grease into the countersink of the
brake housing
Figure 38
Grease O-ring (see arrow) and install it to the axle housing.
Figure 39
Mount two adjusting screws (S) and use the lifting device to
bring the output into contact position with the axle housing.
Then fix the output by means of hexagon screws.
(S) Adjusting screws (M18x15) 5870 204 029

Fix load carrying device (S) with wheel stud!

Figure 40
Mount breather (see arrow).
Figure 41
5871 529 002 8/11

Corporate Division
and Axle Systems
Check brake hydraulics for leakages
 Before starting the test, completely breathe the brake

hydraulics!
Then pressurize the brake temporarily (5x) with p = 100 bar

max!
High-pressure test:
Build up test pressure p = 100 -10 bar max. and close connection
to HP pump via shut-off valve.
A pressure drop of max. 2 % (2 bar) is permissible during a
Figure 42 5-minute testing time!
Low-pressure test:
Reduce test pressure p = 5 bar and close shut-off valve!
No pressure drop is allowed during a 5-minute testing time!
Test media:
Engine oils SAE 10-W corresponds to MIL-L 2104 C,
MIL-L 46152, API-CC, CD, SC, SD, SE,
ATF-oils type A, Suffic A Dexron of II D.
(S) HP pump 5870 287 007

(S) Clutch 0501 207 939
(S) Reduction (M18x1.5) 5870 950 161
(S) Oil collector bottle 5870 286 072
Check operability of DHL
Build up pressure p = 20 bar max. and close connection to HP

pump via shut-off valve.
Lock on:
When rotating the input flange, both outputs must have the same
direction of rotation.
Lock off:
When rotating the input flange one side has no movement or has
the opposite direction of rotation.
Figure 43
 Prior to putting the axle into operation, fill it with oil

according to the related lubrication and maintenance
instructions (5871 529 902)!
5871 529 002 8/12

Order no.: 5871 529 902
Lubrication and Maintenance

Instructions
ZF - MULTITRAC
MT-L 3085 II / 3095 II
ZF Passau GmbH
Donaustr. 25 - 71
D- 94034 Passau
Preface
This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to
be done on ZF units. Due to the continuous technical upgrading of the product, however, the repair of the unit at your
disposal may require both deviating operations and differing setting and testing data.
These lubrication and maintenance instructions are based on the unit’s state-of-the-art at the time of printing.
They were prepared with utmost care in order to avoid errors.
ZF Passau GmbH, however, shall not be liable for any possible errors in figures or descriptions.
ZF Passau GmbH reserves the right to replace these lubrication and maintenance instructions by a successive edition
at any time without advance notice. Upon request, ZF Passau GmbH will advise, which edition is the latest one.
The owner and the user shall be responsible for complying with the safety instructions and for implementing the
maintenance work according to the specified guidelines.
ZF Passau GmbH shall not be liable for any incorrect installation, improper handling, insufficient maintenance,
improperly and incompetently performed work and any consequential damage resulting thereof.
It is imperative to observe the relevant instructions and manuals of the vehicle manufacturer.
Important information regarding technical reliability and operational safety are highlighted by the following symbols:
This symbol serves as a reference to special working procedures,

methods, information, use of auxiliaries etc... indicated in this repair
CAUTIION manual.
This symbol identifies situations in which lacking care might lead to

DANGER personal injury or damage to the product.
ZF Passau GmbH
Donaustr. 25 - 71
94034 Passau
Abt.: ASGI
Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted!
Subject to technical modifications!
Design Level 2010/10

Corporate Division
and Axle Systems
LUBRICATION AND MAINTENANCE INSTRUCTIONS

FOR ZF-AXLES MT-L 3085 II / 3095 II
1. Oil grade:
ZF List of Lubricants TE-ML 05 are authorized for ZF axles MT-L 3085 II / 3095 II..
The list of lubricants is being continuously updated and can be obtained or viewed as follows:
- at all ZF plants
- at all ZF service organizations
- Internet http://www.zf.com/
2. Oil change:
Precondition for a correct oil change is the horizontal installation position of the axle in every direction.
Place the vehicle in a horizontal position.
Clean all drain plugs, filler plugs and level check plugs carefully prior to open them.
Oil drain only immediately after a longer driving time!
3
1
Legend:
1 = Oil drain hole M36x1.5 axle drive housing

2 = Oil drain hole M24x1.5 axle housing
3 = Oil filler hole M36x1.5
4 = Brake breather
5871 529 902 1

Corporate Division
and Axle Systems
2.1 Oil drain:
Loosen oil drain plugs 1 and 2 and drain oil.
2.2 Oil filling:
Fit oil drain plugs 1 and 2 with new O-ring and install them.
Tightening torque . . . . . MA = 50 Nm
Fill up oil until overflow on the oil filler/level check plug (3).
Filling quantity approx. 35 liters.
2.3 Check:
Check oil level after some minutes and refill until the specified level is reached and remains constant.
Fit oil filler / level check 3 with new O-ring and install it.
Tightening torque . . . . . MA = 50 Nm
3. Oil change intervals:
In this connection see specifications in the ZF list of lubricants TE-ML 05.
4. Oil level check:
Check oil level every month, in particular, however, when a vehicle has been put into service with new or repaired
axles or axle parts.
5. Breather:
Prior to initial operation and when changing the oil within the oil change interval, clean breather and check its
operability.
6. Brake:
The following oils are authorized for the pneumatic-hydraulic brake actuation, or actuated via accumulator system
1. Engine oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2. ATF – oils type A, Suffic A, Dexron of II D
5871 529 902 2

Corporate Division
and Axle Systems
CARRY OUT WEAR MEASUREMENT ON THE MULTI DISK BRAKE
Caution:
Make measurement of lining wear at least once per year, in particular, however, in case of modified braking
behaviour, like:
• Brake noises
• Reduced braking power
• Changed deceleration
• Changed brake oil level
• Changed braking pressure
Wear measurement – multi-disk brake

(Figure 1 and 2):
A wear measurement has to be made on both output sides.

Remove screw plug, actuate brake and determine Dimension X
acc. to Figure 1 and 2 by means of feeler gauge.
Dimension X corresponds with thickness of inner clutch disc
on the piston side.
Fig. 1
ATTENTION: Version with paper discs :
If Dim. X < 4,0 mm, the lined
discs on both output sides have “X”
to be replaced!
Version with sinter discs:
If Dim. X < 3,5 mm, the lined
discs on both output sides have
to be replaced!
Then provide the level plug with a new O-ring and install it!
Tightening torque . . . . . . . . . . . . MA = 50 Nm
Fig. 2
5871 529 902 3

WNDJ en SD 00 Workshop Manual Axle

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PART NO.

PRINTED IN JAPAN (K) 2015, 08

Model ZF Axle Parts No.

MT-L 3085 II / 3095 II

Labeling of identification plate 0/4

Conversion table 0/9

Denomination of standard dimensions 0/10

Tightening torques for screws 0/11

TOOLS WS/1 ... WH/5

Special tools WS/1 ... 10

Commercial tools WH/1 ... 5

DISASSEMBLY 1/1 ... 4/8

1. Disassembly output and brake 1/1 ... 7

2. Disassembly axle housing 2/1

3. Disassembly drive 3/1 … 3

4. Disassembly differentials 4/1 … 3

REASSEMBLY 5/1 ... 8/12

5. Reassembly differentials 5/1 … 12

6. Reassembly drive 6/1 … 9

7. Reassembly axle housing 7/1 … 2

8. Reassembly output and brake 8/1 … 12

1. Permanently trained staff

2. Specified equipment, e.g. special tools

3. State-of-the-art genuine ZF spare parts

All work is done there with utmost care and reliability.

This manual is based on the state-of-the-art at the time of printing.

5871 529 002 0/1

5871 529 002 0/2

Structure of the Service Manual

Important information on labor safety

The repair workshop shall be responsible for the training.

The following safety references are used in this manual:

This symbol serves as a reference to special working procedures,

This symbol identifies situations in which lacking care may lead to

5871 529 002 0/3

LABELING OF IDENTIFICATION PLATE

3 = ZF – parts list number

4 = Overall axle ratio/ version with or without ZF – multi-disk differential lock

Note on item 6: See ZF List of Lubricants for ZF axles TE - ML 05 !

INFORMATION ON SPARE PARTS ORDERING

3. ZF – parts list number

4. Make and type of vehicle

5. Denomination of spare part

6. Spare parts number

NOTE: Item 1, 2 and 3 are visible on the identification plate.

5871 529 002 0/4

Examples of contact patterns for the Gleason gear tooth system

Ideal contact pattern:

Contact pattern setting:

5871 529 002 0/5

EXAMPLE 1: Dedendum tooth position

Contact pattern not o.k.

Adjustment: Add a smaller shim to the pinion!

Contact pattern o.k.

5871 529 002 0/6

Example 2: Addendum tooth position

Contact pattern not o.k.

Adjustment: Use a thicker pinion spacer!

Contact pattern o.k.

5871 529 002 0/7

Example 3: “Line” contact pattern

Contact pattern not o.k.

Adjustment: Add a thicker pinion spacer!

Contact pattern o.k.