SM - 695SR - Tier3 - 6front Axles - EN

Copyright ©
590 Super R
695 Super R
SECTION 25 - FRONT AXLES
1. FRONT AXLE 4WD “CARRARO” ................................................................................................................. 3

1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
1.3 FAULT FINDING.................................................................................................................................. 55
2. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 58
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 58
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 62
2.3 FAULT FINDING................................................................................................................................ 115
3. SPECIAL TOOLS...................................................................................................................................... 118
Copyright ©
2 SECTION 25 - FRONT AXLES

Copyright ©
SECTION 25 - FRONT AXLES 3
1. FRONT AXLE 4WD “CARRARO”

1.1 TECHNICAL SPECIFICATIONS
TYPE
Front steering axle, model 26.16
F27203
POWERSHIFT POWERSHUTTLE RATIO

• • 12.8
• • 12.333
Copyright ©
LUBRICATION AND GREASING
Differential oil capacity 6.5 litres (1.70 gal)

Epicyclic reduction gear oil capacity each side 0.7 litres (0.20 gal)
Oil specification:
use recommended oil enriched in additives Akcela Hy-Tran Ultra
Note: do not use synthetic or vegetable oil without consent of the axle MAT3525
manufacturer
Grease specification Akcela Multi-purpose grease
251H-EP
F27204
Fill in excess with MU/EP2 grease
Before assembling, grease indicated surface with POLYMER 400 grease

Copyright ©
3 5 1 4 5 3
5 2 5
5 4 5
F27205
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
Copyright ©
Before draining the oil from axle housing, use the oil
breather (2) to release possible internal pressure. 2
SWARNING
Risk of violent oil ejection.
F27206
To drain the oil remove the level plug (1) and the
drain plug (4).
SWARNING
Drain all oil.

Clean the drain plug (4) and tighten to the requested
torque.
1 4
F27207
Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the plug (1) to the prescribed torque.
1
F27208
Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi- 3
tion [pos.A] and partially unscrew to release possi-
A B
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Remove the plug and drain the oil.
F27209
Copyright ©
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. 3
Tighten the plug (3) to the requested torque.
F27210
Copyright ©
TIGHTENING TORQUES
165 Nm
95 Nm 120 Nm 8 Nm 150 Nm 95 Nm 13 Nm
80 Nm 25 Nm 120 Nm 8 Nm 300 Nm 120 Nm 169 Nm
120 Nm
266 Nm 57 Nm
165 Nm
10 Nm 8 Nm 84 Nm 60 Nm 8 Nm 84 Nm
F27211
Copyright ©
1.2 DISASSEMBLY AND ASSEMBLY
FRONT AND REAR SUPPORT
21
18
20
15 17
16 19
14
12
9
6 8
3 5 13
11
10
7
4
2
1
F27212
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
14
1 2
F27213
Copyright ©
Loosen the bolt (4).

Take the rear support (5) out from the differential
support.
4
F27214
Remove the O-ring (6) from the bush (8) in rear sup-
port (5).
NOTE: this is a destructive operation for the O-ring.
5
7
F27215
Remove the bolt (4).

Remove the bush (8) from the rear support (5).
5 8
4
F27216
Remove the bushes (6) from the rear support (5).

6
F27217
Copyright ©
Remove the cover (11) from differential support with

a lever.
11
F27218
Remove the seal rings (12) and (13) from the cover
(11). 13
NOTE: destructive operation for the seal rings. 12
11
F27219
Remove the bush (9) and the thrust washer (10)

from differential support only if necessary.
NOTE: it is advisable to heat the bush (9) to make

easy this operation; this is a destructive operation
for the bush. 10
9
F27220
Loosen the bolt (19).

Take the front support (20) out from the axle hous-
ing (15). 20
15
19
F27221
Copyright ©
Remove the bolt (19).

Remove the bush (18) from the front support (20). 21
Remove the bushes (21) from front support (20).
20
18
19
F27222
Remove the bush (17) and the thrust washer (16)

from axle housing (15) only if necessary. 15 16

for the bush.
17
F27223
Assembly
Insert the thrust washer (10) into the differential sup-

port.
Heat the bush (9) at 110÷120 °C (230÷248 °F) then
assemble it to the differential support.
If necessary assemble the bush (9) with a pad and
a hammer. 10
9
F27220
Assemble the seal ring (13) to the cover (11) with

the special tool 380002432 and a hammer. 13
Assemble the new O-ring (12) to the cover (11).
Lubricate the O-ring (12) and the seal ring (13). 12
11
F27219
Copyright ©
Assemble the cover (11) to the differential support.
11
F27218
Apply sealant on bushes (6) contact surface.

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.
F27217
Assemble the bush (8) in the rear support (5).
SWARNING
Align the bush hole with the bolt (4) hole.
Assemble the bolt (4).

5 8
4
F27216
Lubricate with grease a new O-ring (7).

Insert the O-ring (7) in the rear support (5).
5
7
F27215
Copyright ©
Insert the rear support (5) on the differential support.
SWARNING
Do not damage the O-ring when inserting the rear
support on the central body. 5
Tighten the bolt (4) to the requested torque.
4
F27214
Assemble the flange (2) to the pinion shaft end (14).

Lock the flange (1) with the bolt (2) and the nut (3).
Tighten the nut (3) to the requested torque.
14
1 2
F27213
Insert the thrust washer (16) into the front support

seat. 15 16
Heat the bush (17) at 110÷120 °C (230÷248 °F) then
assemble it to the axle housing (15).
NOTE: if necessary assemble the bush (17) with a

pad and a hammer.
17
F27223
Apply sealant on the bushes (21) contact surface.

Assemble the bushes (21) into the front support (20) 21
with a pad and a hammer.
20
F27224
Copyright ©
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
20
SWARNING 18
19
F27225
Insert the front support (20) on the axle beam.

20
19
F27226
Copyright ©
STEERING CYLINDER
19
12
11
21 10
17
20
15
18
16 7
14 8 9
6
13
5
4
3
2 1
F27227
Disassembly
Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).
SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
NOTE: this is a destructive operation for the nut (1). 1

2
F27228
Repeat the whole sequence at the other side.

Copyright ©
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the 11
conditions.
Unscrew the fastening screws (6) and take the
6
steering cylinder (7) out of its housing, if necessary 12
use a rubber hammer.
4
Remove only parts that need to be overhauled and/ 10
or replaced. 7
3 5
F27229
Remove the cylinder head (15) from the cylinder

body (19) and remove it from the rod (17). 21
Remove the rod (17) from the cylinder body (19). 19
Remove all the seals and O-rings (13, 14, 16, 18, 20
and 21) from the cylinder body (19), the cylinder 16 20
head (15), and the rod (17). 14
13
18
17
15
F27230
Assembly
Assemble new seals and O-rings (13, 14, 16, 18, 20

and 21) on the cylinder head (15), on the rod piston 21
(17) and on the cylinder body (19). 19
16
14 20
13
18
17
15
F27231
Assemble the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).
17
15
19
F27232
Copyright ©
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod 11
(17), then tighten to the requested torque.
6
12
4
10
7
17
3 5
F27233
Install the steering cylinder (7) already assembled

on the central body. 6
Assemble and tighten the screws (6) to the request-
ed torque.
F27234
Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be in- 11 12
serted into the swivel housing (8).
NOTE: it is important to unscrew the locknut (11) to

carry out this operation.
Repeat the whole sequence of the mentioned oper-

ations to the other side.
8
F27235
Assemble the ball joint of the tie rod (3) into its hous-
ing on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
1
F27236
Copyright ©
Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been 11 12
carried out.
F27238
Copyright ©
EPICYCLIC REDUCTION GEAR
10
9
8
7
6
5
4
2
1
3
F27239
Disassembly
Drain the oil completely from the planetary carrier.
F27240
Copyright ©
Unscrew and remove both fastening screws (3) of

the planetary carrier (1). 3
1
F27241
Remove the planetary carrier (1) from the wheel hub

and collect the relative O-ring (5). 1 5
Position the planetary carrier (1) on a workbench
and check its wear conditions.
F27242
If required replace the planetary gears as follows:

Z remove the snap rings (10) on every pin (4); 7
Z remove the triangular plate (9); 6
Z take the planetary gears (8) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions;
Z collect the thrust washer (6).
10
NOTE: with new planetary gears is advisable to as- 9
sembly new roller bearings. 8
4
F27243
Assembly
Collect all epicyclic reduction gear parts: the plane-

tary carrier (1), the thrust washers (6), the needle 7
bearings (7), the planetary gears (8), the triangular 6
plate (9) and the snap rings (10) of every pin.
NOTE: with new planetary gears is advisable to as-

sembly new roller bearings.
10
9
8
1
F27244
Copyright ©
Position the planetary carrier (1) on a workbench.

Insert the thrust washers (6) and the epicyclic gears 9
1 1 10
(8) in the planetary carrier pins.
Insert the needle bearings (7) in the epicyclic gears
(8).
NOTE: grease well the needles.
Assemble the triangular plate (9) and the related

snap rings (10).
6 7 8
F27245
Assemble a new O-ring (5) on the planetary carrier

(1). 1
Assemble the planetary carrier (1) on the wheel hub. 5 1
F27246
Assemble the screws (3) and tighten to the request-

ed torque. 3
1
F27241
Top up the oil on the wheel hub.

Assemble the oil plug (2) on the planetary carrier (1) 2
and tighten to the requested torque.
F27247
Copyright ©
WHEEL HUB
28
19
27
18
24
14
22
13
26
12
25
23
11
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27248
Disassembly
Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint.
With the lever push the double U-Joint in the direc-
tion of the wheel hub to allow the lock ring removal.
SWARNING
Do not damage the double U-Joint.
14
F27249
Copyright ©
Remove the lock ring (1) from the double U-Joint

shaft. 3 2
Collect the double U-Joint shaft washers (2) and (3).
F27250
Unscrew and remove the fastening screws (5) from

the wheel carrier (7).
7
F27251
In order to remove the wheel carrier group from its

housing, screw two of the just removed screws (5) 5
in the threaded extraction holes.
Extract and remove the wheel carrier (7) together 7
with the epicyclic ring gear (4).
4
F27253
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- 6
cial tool 380002223.
7
F27252
Copyright ©
Remove the wheel hub (11) using levers and a ham-

mer to facilitate the operation. 15
NOTE: collect the bearing (9). 11
F27254
Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a lever.
NOTE: destructive operation for the seal ring (13). 7

5
Remove the bearing cups (9) and (12) using a ham-
mer and a suitable drift.
9
Remove the bearing (12) from the swivel housing
end using a suitable extractor. 8
F27255
Unscrew and remove the fastening screws (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
rent safety regulations to guarantee operator’s safe- 14
ty.
Remove the king pins (16) and (18).

F27256
Remove the swivel housing (14) from the axle beam

and from the short shaft of the double U-Joint.
14
F27257
Copyright ©
Remove the spacer (27) from the upper king pin

housing.
27
F27258
Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a lever.
NOTE: destructive operation for the seal ring (23).

22
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
14 23
F27259
Assembly
If it has been previously removed, reassemble the

steering stop composed by the screw (21) and the
nut (20).
NOTE: do not tighten the nut (20) until the steering

angle adjustment has been done.
20 21
F27260
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
23 14
press.
Assemble the seal ring (23) on the swivel housing
22
(14) with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
F27261
Copyright ©
Assemble the spacer (27) in the upper king pin

housing.
27
F27258
If the cone (15) of the spherical joint has been pre-

viously removed, reassemble it to the lower king pin
(16) using the special tool 380002662 under a
15
press.
Grease carefully the seats of king pin (16) and (18)
16 28
25
with specific grease.
Position the belleville washers (25) and (28) on the 18 25
king pin (16) and (18) housings.
F27262
Secure the swivel housing (14) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 14
ring.
Assemble the swivel housing (14) on the axle beam.
F27257
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
Copyright ©
Assemble both bearing cups (9) and (12) to their

wheel hub (11) housings using the special tool
380002663 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002227 and a hammer. 9 12 13
11 11
NOTE: do not lubricate the seal ring (13).
F27264
Assemble the bearing (12) on the swivel housing

(14) end. 14
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing (9). 12 9
F27265
Position the wheel carrier (7) on a workbench and

force the bushes (6) to the carrier surface level with 6 7
the special tool 380002223.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.
F27266
Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8). 8
7
4
F27267
Copyright ©
Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.
F27268
Insert all the hub dowel bushes (6) completely with

the special tool 380002223 and a hammer. 6 5
Apply sealant on fastening screws (5) thread.
Assemble the wheel carrier (7) fastening screws (5) 7
F27269
The special operation “Set Right” of the bearings (9)

and (12) does not require preload or backlash ad-
justment. Anyway, before assembling new compo-
nents check the indicated dimensions.
A= 11.975 ÷ 12.025 (0.471 ÷ 0.473) C A C

B= 52.229 ÷ 52.279 (2.056 ÷ 2.058)
C= 20.000 ÷ 20.100 (0.787 ÷ 0.971)
B
F27270
Insert a lever between the swivel housing and the

axle beam and fit it into the double U-Joint.
tion of the wheel hub to make easier the lock ring in-
sertion.
F27271
Copyright ©
Slide the thrust washers (2) and (3) onto the double
U-Joint shaft end. 3 2
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.
NOTE: check that the lock ring (1) is correctly fitted

1
in its seat.
Push the double U-Joint thoroughly.
F27250
Copyright ©
DOUBLE U-JOINTS
1 2
4
5
6
F27272
Disassembly
Remove the two double U-Joints (6) from the axle

beam (1).
1
6
F27273
Copyright ©
Remove the seal rings (5) from the axle beam (1).
NOTE: destructive operation for the seal rings (5).

4
Remove the bush (4) from the axle beam (1) only if 5
the wear conditions require this.
SWARNING
Be careful not to damage the bush seat.
5
F27274
Remove the upper king pin bush (2) and the ball
bearing cup (3) from the king pin seats using a suit-
able extractor only if the wear conditions require
this.
F27275
Assembly
Cool the upper king pin bush (2) and the ball bearing
cup (3) at a temperature lower than -100 °C (-148 °F)
with liquid nitrogen.
2
SWARNING
Wear safety gloves.
Assemble the bush (2) on the upper king pin seat

with the special tool 380002664 and a hammer. 3
Assemble the ball bearing cup (3) on the lower king pin
seat with the special tool 380002662 and a hammer.
F27276
Assemble the bush (4) on the axle beam (1) with the
special tool 380002665 and a hammer.
Assemble the seal ring (5) on the axle beam with the
1
4
NOTE: grease carefully the seal rings. 5
F27277
Copyright ©
Assemble the seal ring (5).
SWARNING 5
Positioning the seal ring (5) as in figure.
F27278
Insert the double U-Joint (6) inside the axle beam

(1).
SWARNING
Be careful not to damage the seal ring.
1
6
F27273
Copyright ©
DIFFERENTIAL SUPPORT
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27282
Disassembly
Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
14
SWARNING
Support the differential support with a rope or other 2
appropriate means.
1
F27283
Copyright ©
Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9 9
8 8
F27284
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3
F27285
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27286
Remove the 4 screws (12) and remove both half-

collars (11).
NOTE: check that the bushes (10) remains in their 12

housings.
11
10
F27287
Copyright ©
Remove the differential housing (5).

The bearing (4) and (6) are removed together with
the differential housing.
4
SWARNING 6
Do not invert the bearings if they are not replaced.
5
F27288
Assembly
Assemble the bearings (4) and (6) on the differential

housing (5).
SWARNING
4
6
5
F27289
Position the complete differential box with bearings

on the differential carrier.
SWARNING
Check the right side of the bevel crown assembly.
F27290
Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both collars with their fastening bolts (12).
11
10
F27291
Copyright ©
Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded. 3
Check that the differential bearings are well settled; 7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27292
Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.
F27293
Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, meas-
ured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm (0.007÷0.009 in)
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27294
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.
F27295
Copyright ©
Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27293
Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
(T = (P+8.76) ÷ (P+13.2) lbf)
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.
F27296
SWARNING
All preloadings must be measured without seal ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinion-
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
ring gear backlash value unchanged. F27297
Copyright ©
Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8
F27298
Tighten the bolts (12) of both half collars (11) to the

requested torque.
12
13
F27299
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap- 13
propriate detergents.
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier. 14
NOTE: check that two dowel pins (13) are in their 13
housing.
F27300
Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
14
F27301
Copyright ©
Bevel gear marking test
To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
Copyright ©
DIFFERENTIAL GROUP
Disassembly
Use an extractor to remove the bearing (12) from

the bevel pinion.
12
F27306
Copyright ©

the bevel pinion.
F27307
Unscrew all fastening screws (1) of the bevel gear

crown (11). 11
SWARNING 1
This operation makes both differential half boxes
free, so take care not to lower the inner compo-
nents.
F27308
Remove the bevel gear crown (11) by means of a

hammer.
11
F27309
Check marking points (3) and (10) that will be useful

during the assemblage.
10
F27310
Copyright ©
Disassemble the two differential half housings (3)

and (10).
Disassemble all the components.
Check the operating and wear conditions of the
components.
Assembly
Position a half housing (3) on a workbench and as-

semble all inner components: locking differential
counterdisc (4), sun gears (5), spider (9), spider
gear (7), thrust washer (6), pin (8).
Assemble the two half housings of differential unit

(3) and (10).
10
SWARNING
Carefully check that the marks of both differential
half boxes coincide.
F27310
Assemble the bevel gear crown (11) by using a

hammer.
11
F27314
Copyright ©
Apply Loctite 242 on thread of the screws (1).
1
F27316
Tighten the screws (1) to the requested torque.
NOTE: fix differential housing in the vice.
F27315
Press the bearing (12) or assemble after preheat-

ing.
12
F27317
Press the bearing (2).
F27318
Copyright ©
PINION GROUP
Disassembly
Position the differential carrier in a vise.

Unscrew the locknut (10) using special tool
380002218.
NOTE: this operation will irretrievably damage the

locknut (10).
10
F27320
Copyright ©
Remove the ring nut (10) and collect its retaining

washer (9).
9
10
F27321
Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8
SWARNING
Take care not to lower the bevel pinion (1). 5
1
Collect the washers (4) and (6), the collapsible
spacer (5) and the bearing (8).
6
4
F27322
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and
a hammer. 3
8
F27326
To remove the bearing (3) of the bevel pinion (1),

use a standard extractor.
Collect the bearing (3) and the underlying shim (2).
3
F27324
Copyright ©
Check all pinion components for wear.
SWARNING
The ring nut (10) and the collapsible spacer (5) must 5
be replaced when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8) using the special
drifts and a hammer. 3
8
F27326
Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.
F27327
Insert the bearing (3) and (8) in their housings.

Assemble the “false pinion” 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated.
8
10
F27328
Copyright ©
Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
7
F27329
Assembly diagram of the “false differential box”

tools 380000407 + 380000440 on the bearing differ-
ential support seats. X
Use a depth gauge to measure distance “X” (dis-
tance between the axis of the differential bearings
and the point at which the pinion head is supported, X
or base of the bearing).
F27330
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).
S = X-V mm
V
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
Copyright ©
Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing (3) and (8).
8
10
F27328
Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool 380002224 under a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new collapsible
spacer (5).
1 1
NOTE: use always a new collapsible spacer (5).
F27334
Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing (8) into the pin- 8
ion shaft.
In order to force the bearing (8) into position, use the
special tool and a hammer.
7
It is advisable to offer resistance, for example a
sledge, to the beating force. 1
F27335
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
9
10
F27321
Copyright ©
Screw the ring nut (10) in, using the wrench

380002218 for ring nut and for pinion retainer.
SWARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10
NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27336
to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.
Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
P = 9.2÷13.7 daN
(P = 20.7÷30.8 lbf)
SWARNING
All preloadings must be measured without the seal F27337
ring.
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
Copyright ©
TOE-IN / STEERING ANGLE
11
1 2 3 11
3 2 1
5 5
4 4
F27339
Toe-in
Put two equal 1 m (3.3 ft) long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.
SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
Copyright ©
Measure the distance in mm (in) M between the

bars ends with a tapeline.
NOTE: keep the minimum value, swinging the

measurement point.
F27341
Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5
M -05
F27342
If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1
F27343
Copyright ©
After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
1 2
F27344
Steering angle adjustment
Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.
F27345
Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.
F27346
Adjust the mechanical steering stop, screwing in or

out the stop bolt (4), locking it with the locknut (5) to
the requested tightening torque.
5 4
F27347
Copyright ©
Steer completely towards the other side and repeat

the same operation.
F27348
Copyright ©
1.3 FAULT FINDING
PROBLEM CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.
2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.
3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with
bigger radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both
tyres.
4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.
5. Bent half shaft

Replace half shaft.
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.
8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings etc.
Replace whenever necessary.
9. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
11. Incorrect use of the product

See the vehicle producer’s instructions once again.
Copyright ©
PROBLEM CAUSE ACTION

Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set.
outer side the one foreseen Follow carefully the recommended
Incorrect gear adjustment operations for the adjustment of
(excessive backlash) bevel gear set backlash.
Pinion nut loose
Ring gear tooth broken side Load bump Replace bevel gear set.
Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of
Pinion nut loose bevel gear set backlash.
Pinion or ring gear teeth worn Insufficient lubrication Replace bevel gear set.
Contaminated oil Follow carefully the recommended
Incorrect lubrication or depleted operations for the adjustment of
additives bevel gear set backlash.
Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact the recommended program.
between pinion and ring
Overheated ring and pinion teeth Prolonged functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
Incorrect lubrication level and replace at recommended
Low oil level program.
Contaminated oil
Pinion teeth pitting Excessive use Replace bevel gear set.
Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Axle beam body bent Vehicle overloaded Replace axle beam body.
Vehicle’s accident
Load bump
Worn out or pitted bearings Insufficient lubrication Replace bearings.
Contaminated oil Use correct lubrication, fill up to the
Excessive use right level and replace at
Normal wear out recommended intervals.
Pinion nut loose
Oil leakage form gaskets and Prolonged functioning at high Replace the gasket or seal and
seals temperature of the oil matching surface if damaged.
Oil gasket assembled incorrectly Use correct lubrication and replace
Seal lip damaged at recommended intervals.
Contaminated oil
Excessive wearing out of input Exhaustive use Replace the flange.
flange spline Pinion nut loose Check that the pinion spline is not
Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set.
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential Check and/or replace other
components differential components.
Copyright ©
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm (0.004 in)
thickness lower than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
Copyright ©
2. FRONT AXLE 4WS “CARRARO”

2.1 TECHNICAL SPECIFICATIONS
TYPE
Front steering axle, model 26.28
F27378
POWERSHIFT SELF LOCKING RATIO

• • 18.46
Copyright ©
LUBRICATION AND GREASING
Oil capacity 11.0 litres (2.90 gal)

Oil specification:
use recommended oil enriched in additives
Akcela Nexplore MAT3525
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
Grease specification Akcela Multi-purpose grease
251H-EP
1 4
3 5 5 3
5 2 5
5 5
F27379
DESCRIPTION POSITION
Oil filling and level plug 1
Oil breather 2
Filling, level and drain plug of epicyclic reduction gear oil 3
Oil drain plug 4
Greasing points 5
Copyright ©
Before draining the oil from axle housing, use the

breather (2) to release possible internal pressure. 2
SWARNING
F27206
To drain the oil remove the level plug (1) and the
drain plug (4).
SWARNING
Drain all oil.

Clean the drain plug (4) and tighten to the requested
torque.
1 4
F27207
Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the level plug (1) to the prescribed torque.
1
F27208
Before draining the oil from wheel end rotate the

wheel end so that the plug (3) is at the highest posi- 3
tion [pos.A] and partially unscrew to release possi-
A B
ble pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [pos.B].
Remove the plug and drain the oil.
F27209
Copyright ©
Rotate the wheel end so that the hole (3) is in the po-
sition shown in figure.
Fill to the bottom of the fill plug hole with specified
oil. 3
Tighten the plug (3) to the requested torque.
F27210
Copyright ©
2.2 DISASSEMBLY AND ASSEMBLY
FRONT AND REAR SUPPORT
21
18
22
17
15 16
19
23
7
6
8
5
11
1 14
3 10
4
9
12
13
2 F27380
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
1
3
2
F27381
Copyright ©
Remove the oil seal (13).
13
F27382
Unscrew the screws (11) and remove the flange

(12).
12
11
F27383
Loosen the fastening screw (4).

Take the rear support (5) out from the differential
support.
4
F27384
Remove the O-ring (6) from the bush in rear support

(5).
NOTE: this is a destructive operation for the O-ring

(7).
5
F27385
Copyright ©
Remove the bolt (4) and the lube nibble (9).

Remove the bush (8) from the rear support (5).
8
5
4
9
F27386
Remove the bushes (6) from the rear support (5).

6
F27217
Remove the washer (10) from the differential sup-

port only if necessary.
10
F27387
Loosen the fastening screw (19).

Take the front support (20) out from the axle hous- 20
ing (15). 15
19
F27388
Copyright ©
Remove the O-ring (22).

Remove the bolt (19) and the lube nibble (23). 21
Remove the bush (18) from the front support (20).
Remove the bushes (21) from front support (20).
20
19
18
23
22
F27389
Remove the bush (17) and the washer (16) from the
axle housing (15) only if necessary. 17
15
for the bush.
16
F27390
Assembly
Insert the washer (10) into the differential support.
10
F27387

Assemble the bushes (6) to the rear support (5) with 6
a pad and a hammer.
F27217
Copyright ©
Assemble the bush (8) in the rear support (5).
SWARNING

5 8
4
F27216
Lubricate with grease a new O-ring (7).

Insert the O-ring (7) in the rear support (5).
5
7
F27215
Insert the rear support (5) on the differential support.
SWARNING
Do not damage the O-ring when inserting the rear 5
support on the central body.

Assemble the lube nibble (9).
4
9
F27391
Insert the washer (16) into the front support seat.

Heat the bush (17) at 110÷120 °C (230÷248 °F) then 17
assemble it to the axle housing (20). 15
NOTE: if necessary assemble the bush (17) with a
pad and a hammer.
16
F27390
Copyright ©

Assemble the bushes (21) to the front support (20) 21
with a pad and a hammer.
20
F27224
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
SWARNING 20
Align the bush hole with the bolt (19) hole. 19
18
Mount the bolt (19). 22
Assemble O-ring (22).
F27393
Insert the front support (20) on the axle beam.

Tighten the bolt (19) to the requested torque. 20
Assemble the lube nibble (23).
19
23
F27394
Assemble the flange (12) and fasten by tightening

the screws (11).
12
11
F27383
Copyright ©
Assemble the seal ring (13) use the special tool

380002225.
13
F27382
Assemble the flange (2) to the pinion shaft end.

Lock the flange (1) with the bolt (2) and the nut (3).
Tighten the nut (3) to the requested torque.
1
3
2
F27381
Copyright ©
STEERING CYLINDER
24
23
22
10
21
9
13 20
8
19
14 18
7
6
5
4
3
17 12
16 11
15
1
F27396
Disassembly
Loosen the nut (1) with enough turns till it is protrud-

ing over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel hous-
ing (2).
SWARNING
Don’t beat on the threaded pin end of the tie rod (3). 3
NOTE: this is a destructive operation for the nut (1). 1

2
F27228
Repeat the whole sequence at the other side.

Copyright ©
Remove the tie rods (3) and (10) by loosing the nuts
(4) and (9) with a suitable wrench, then check the 13
13
conditions.
Unscrew the fastening screws (13) and take the 10
14
steering cylinder (7). 9
Remove only parts that need to be overhauled and/ 8
15
or replaced. 7
6
5
4
3
F27397
Remove the cylinder head (18) from the cylinder

body (22) and remove it from the rod (20). 23
Remove the rod (20) from the cylinder body (22). 20
Remove all the seals and O-rings (16, 17, 19, 21, 23
and 24) from the cylinder body (22), the cylinder 24
head (18), and the rod (20). 22
17
16 21
19
18 F27398
Assembly
Assemble new seals and O-rings (16, 17, 19, 21, 23

and 24) on the cylinder head (18), on the rod piston 23
(20) and on the cylinder body (22).
24
17 22
16 21
20
19
18
F27392
Assemble the cylinder head (18) on the rod (20).

Slide the pre-assembled rod (20) into the cylinder
body (22).
22
20
18
F27399
Copyright ©
Assemble the tie rods (3) and (8), the ball joints (3)
and (10), the nuts (4) and (9) to the ends of the rod,
then tighten with a dynamometric wrench to the re-
quested torque. 10
9
8
7
6
5
4
3
F27400
Install the steering cylinder (7) already assembled

on the central body.
Assemble and tighten the screws (13) with dynamo-
metric wrench to the requested torque.
Assemble bracket (14).
Align the swivel housing (11) with the axle.

Screw the tie rod (10) so that its ball joint can be in- 9 10
serted into the swivel housing (11) arm.
NOTE: it is important to unscrew the locknut (9) to

carry out this operation.

11
F27402
Insert the ball joint of the tie rod (3) into its housing
on the swivel housing (2). 3
Assemble and tighten the locknut (1) to the request-
ed torque.
1
F27236
Copyright ©
Screw the locknuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been car- 4 9 3 10
ried out.
F29526
Copyright ©
EPICYCLIC REDUCTION GEAR
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
Drain the oil completely from the planetary carrier.
F27240
Copyright ©
Unscrew and remove both fastening screws (3) of

the planetary carrier (1). 3
1
F27241
Remove the planetary carrier (1) from the wheel

hub.
Position the planetary carrier (1) on a workbench
and check its wear conditions.
F27405
If required replace the planetary gears as follows:

Z unscrew the screws (11) on every pin (4); 4 10
Z remove the washer (9) and the washer (8);
Z take the planetary gears (7) out of the pins;
Z collect the roller bearings (7), checking their condi-
tions; 11
Z collect the washer (6). 9
8
NOTE: with new planetary gears is advisable to as- 7
sembly new roller bearings. 6
5
F27406
Assembly
Position the planetary carrier (1) on a workbench.

Insert in the pins of the planetary gears carrier the 1 10
washers (5) and the planetary gears (7) complete
with rollers (6).
Assemble the washers (8) and fasten them with the
pins (10). 11
Fit the washers (9) and screw in the screws (11) by 9
tightening them at the prescribed torque. 8
7
NOTE: with new planetary gears it is advisable to 6
assembly new roller bearings. 5
F29008
Copyright ©
Assemble the epicyclic reduction gear (1) on the

wheel hub.
F27405
Assemble the screws (3) and tighten to the request-

ed torque. 3
F27407
Top up the oil on the wheel hub.

Fit the filling/drain and level oil plug (2) on the plan- 2
etary carrier (1) and tighten to the requested torque.
F27408
Copyright ©
WHEEL HUB
19
26
18
24
27
14
22
13
12
25
11 23
10
9
8 15
7 21
4 16 20
3 17
2 5 6
F27409
Disassembly

tion of the wheel hub to allow the lock ring removal.
SWARNING
Do not damage the double U-Joint.
14
F27410
Copyright ©
Remove the lock ring (1) from the double U-Joint

shaft. 3 2
Collect the double U-Joint shaft washers (2) and (3).
F27250
Unscrew and remove the fastening screws (5) from

the wheel carrier (7).
7
F27251
In order to remove the wheel carrier group from its

housing, screw two of the just removed screws (5) 5
in the threaded extraction holes.
Extract and remove the wheel carrier (7) together 7
with the epicyclic ring gear (4).
4
F27253
Remove the steel lock ring (8) and disjoin the wheel
carrier (7) from the epicyclic ring gear (4). 8
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the spe- 6
cial tool 380002667.
7
F27252
Copyright ©
Remove the wheel hub (11) using levers and a ham-

mer to facilitate the operation. 15
NOTE: collect the bearing (9). 11
F27254
Position the wheel hub (11) on a flat surface and re-

move the seal ring (13) with a lever. 13
12
NOTE: destructive operation for the seal ring (13). 11
Remove the bearing cups (9) and (12) using a ham- 10
mer and a suitable drift. 9
Remove the bearing (12) from the swivel housing
end using a suitable extractor.
F27412
Unscrew and remove the fastening screws (19) and

(17) from the upper (18) and lower (16) king pin.
17 19
SWARNING 16 18
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a belt or a rope to a
hoist or any other supporting device; observe all cur-
rent safety regulations to guarantee operator’s safe- 14
ty.
Remove the king pins (16) and (18).

F27256
Remove the swivel housing (14) from the axle beam

and from the short shaft of the double U-Joint.
14
F27257
Copyright ©
Collect the belleville washers (25) and (26).
26
25
F27413
Position the swivel housing (14) on a flat surface

and take the seal ring (23) out with a lever.
NOTE: this is a destructive operation for the seal

ring. 22
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
14 23
F27259
Assembly
If it has been previously removed, reassemble the

steering stop composed by the screw (21) and nut
(20).
NOTE: do not tighten the nut (20) until the steering

angle adjustment has been done.
20 21
F27260
Assemble the bush into the swivel housing (14) with

the special tool 380002668 and a hammer or a
23 14
press.
Assemble the seal ring (23) on the swivel housing
22
(14) with the special tool 380002669 and a hammer.
Grease carefully the seal ring (23).
F27261
Copyright ©
If ball joints (15) and (27) have been previously re-

moved, reassembly them on the lower (16) and up-
per king pin (18).
Grease well the king pin housings (16) and (18) with 27 15
specific grease. 26
Position the Belleville washers (25) and (28) on the 18 16
king pin housings. 25
F27414
Secure the swivel housing (14) with a belt or a rope

to a hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal 14
ring.
F27257
Assemble the king pins, the lower (16) and the up-
per (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
Assemble both bearing cups (9) and (12) to their

wheel hub (11) housings using the special tool
380002222 under a press or with a hammer.
Insert the seal ring (13) into the wheel hub (11) with
the special tool 380002213 and a hammer. 13 9 12
NOTE: do not lubricate the seal ring (13). 11 11
F27525
Copyright ©
Assemble the bearing (12) on the swivel housing

(14). 14
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing (9). 12 9
F27265
Position the wheel carrier (7) on a workbench and

force the bushes (6) to the carrier surface level with 6 7
the special tool 380002667.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.
F27266
Preassemble the wheel carrier (7) and the epicyclic

ring gear (4) with the lock ring (8). 8
7
4
F27267
Assemble the wheel carrier group on the wheel hub

using the two projecting bushes as dowel pins and
screw the relative screws in order to put in contact
the ring bevel gear with the wheel hub.
F27268
Copyright ©
Force all the hub dowel bushes (6) completely with

the special tool 380002667 and a hammer. 6 5
Apply sealant on fastening screws (5) thread.
Assemble the wheel carrier (7) fastening screws (5) 7
F27269

tion of the wheel hub to make easier the lock ring in-
sertion.
14
F27410
Assemble the thrust washers (2) and (3) into the

double U-Joint shaft end.
Insert the lock ring (1) at the end of the splined hub
and push it into its seat.
NOTE: check that the lock ring (1) is correctly fitted

in its seat.
3 2 1
F27416
Copyright ©
DOUBLE U-JOINTS
1
2
3
4
F27417
Disassembly
Remove the two double U-Joints (4) from the axle

beam (1).
1
4
F27418
Copyright ©
Remove the seal rings (3) from the axle beam (1).
1
NOTE: destructive operation for the seal rings (3). 2
3
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
SWARNING
Be careful not to damage the bush seat.
3
F27419
Assembly
Assemble the bush (2) on the axle beam (1) with the
Assemble the seal ring (3) on the axle beam with the
1
2
NOTE: grease carefully the seal rings. 3
F27420
Assemble the seal ring (3).
F27421
Insert the double U-Joint (4) inside the axle beam

(1).
SWARNING
Be careful not to damage the seal ring.
1
6
F27273
Copyright ©
DIFFERENTIAL SUPPORT GROUP
9 8 13
12
11
10
7
6
14
8
5
4
2 3
1
F27411
Disassembly
Drain the oil completely from the differential.

Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
SWARNING
Support the differential support with a rope or other
appropriate means.
2
14
1
F27501
Copyright ©
Loosen and remove the screws (9) to take out the

two ring nut retainers (8). 9
9
8
8
F27395
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent ref-
erence marks to avoid inverting them during re-as-
sembly. Mark the area between the ring nuts (3) and 11
(7) and the differential support (1) as well.
3
F27422
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27423
Remove the 4 screws (12) and remove both half-

collars (11).
NOTE: check that the bushes (10) remains in their 12

housings.
11
10
F27424
Copyright ©
Remove the differential housing (5).

The bearing (4) and (6) are removed together with
the differential housing.
4
SWARNING 6
Do not invert the bearings if they are not replaced. 5
F27425
Assembly
Assemble the bearings (4) and (6) on the differential

housing (5).
SWARNING
4
6
5
F27289
Position the complete differential box with bearings

on the differential carrier.
SWARNING
Check the right side of the bevel crown assembly.
F27427
Move the differential group so to place the bevel

crown gear on the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using 12
the previously traced reference marks.
Lock both collars with their fastening bolts (12). 11
10
F27428
Copyright ©
Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled; 3
7
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27429
Position a magnetic-base dial gauge on the differen-

tial support, so that the feeler stylus touches the sur-
face of one tooth of the crown gear with a 90° angle.
F27293
Lock the pinion and move the crown gear alterna-

tively and note the pinion-ring gear backlash, meas-
ured with the comparator.
Repeat the operation on 2 or more points (teeth), ro-
tating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.18÷0.25 mm (0.007÷0.009 in)
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27430
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the giv-
en tolerance range, unscrew the adjuster ring A A
nut (3) and screw in the adjuster ring nut (7) by
the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the B B
same measure.
F27295
Copyright ©
Once the adjustment of the pinion-ring gear back-

lash has been carried out, check also that there is a
minimum preloading on the differential box bear-
ings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27431
Once the pinion-ring gear backlash has been estab-

lished, measure the total preloading (T) of the bear-
ings (pinion-crown bevel gear system), using a
dynamometer whose cord is wound on the pinion
splined end. The measured value should be within
the following range:
T = (P+3.90) ÷ (P+5.90) daN
(T = (P+8.76) ÷ (P+13.2) lbf)
where P is the effectively measured pinion preload-
ing.
See section “Pinion assembly”.
F27432
SWARNING
All preloadings must be measured without seal ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of A A
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
ring gear backlash value unchanged. B B
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and
ring gear backlash value unchanged. F27297
Copyright ©
Once all the adjustment operations have been com-

pleted, fit the ring nut retainers (8) and their screws 9
(9), tightening them to the requested torque.
8
F27298
Tighten the bolts (12) of both half collars (11) to the

requested torque.
12
11
F27434
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with ap-
propriate detergents. 13
Spread a film of adhesive on the contact surface be-
tween the axle beam (14) and the differential carrier
(1).
NOTE: check that two dowel pins (13) are in their

housing.
14
F27435
Position the differential support (1) on the axle hous-

ing (14), and tighten the retaining screws (2) to the
requested torque.
2
14
1
F27501
Copyright ©
Bevel gear marking test
To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should be always carried out on
the ring bevel gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
Z
OK
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in or-
der to adjust the backlash. X
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in or-
der to adjust the backlash.
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
1
F27304
Copyright ©
DIFFERENTIAL GROUP (STANDARD)
8
1
11
10
9
13
12
7
6
8
7
6
5
4
3
2
F27437
Disassembly

the bevel pinion.
10
F27438
Copyright ©
Use an extractor to remove the bearing (2) from the

bevel pinion.
F27307

crown (11). 11
SWARNING 1
nents.
F27308

hammer.
11
F27309

9
F27439
Copyright ©
Remove the planetary gear (5) and the shim (4).

4
F27440
Remove the differential pin (8), the planetary gear

(7) and the spheric washer (6).
6 6
7 7
F27441
Remove the planetary gear (12) and the shim (13).

12
13
F27442
Assembly
Apply a thin layer of Molicote G-n plus paste on the

half housing of differential (3) and (9). 3 9
SWARNING
Remove rests of dope.
F27443
Copyright ©

planetary gears (5), (12), and on the planetary gears 7
(7).
12
F27444
Assemble the planetary gear (12) with the shim (13).

12
13
F27442
Assemble the differential unit pin (8) and the plane-

tary gears (7) and the spheric washers (6).
6 6
7 7
F27441
Assemble the planetary gear (5) with the shim (4).

4
F27440
Copyright ©
Assemble the two half housings of differential unit

(3) and (9).
9
SWARNING
half boxes coincide.
F27439
Assemble the bevel gear crown (11) by using a

hammer.
11
F27314
Apply Loctite 242 on the thread of the screws (1).
1
F27316
F27315
Copyright ©

ing.
10
F29010
F27318
Copyright ©
DIFFERENTIAL GROUP (SELF-LOCKING)
14
10
13
8
12
9
5
1
4
6
11
10
8
9
7
6
5
4
3
2
F27448
Disassembly

the bevel pinion.
13
F27449
Copyright ©
Use an extractor to remove the bearing (2) from the

bevel pinion.
F27307

crown (14). 14
SWARNING 1
nents.
F27446

mallet.
14
F27450

12
F27451
Copyright ©
Remove the discs (4) and (5).

4 5
F27452
Remove the planetary gear (11).

11
F27453
Remove the differential pin (10), the planetary gear

(8) and the spheric washers (9).
9 9
8 8
10
F27454
Remove the planetary gear (7).
F27455
Copyright ©
Remove the discs (4) and (5).
4 5
F27456
Assembly

half housings of the differential (3) and (12). 3 12
SWARNING
Remove rests of dope.
F27457

planetary gears (7), (11), and on the planetary gears 8
(8).
11
F27458
Assemble the discs (4) and (5).
4 5
F27456
Copyright ©
Assemble the planetary gears (11).
F27455
Assemble the differential unit pin (10) and the plan-

etary gears (8) and the spheric washers (9).
9 9
8 8
10
F27454
Assemble the planetary gears (7).

7
F27459
Assemble the discs (4) and (5).

4 5
F27452
Copyright ©
Assemble the two half housings of the differential

unit (3) and (12).
12
SWARNING
half housings coincide.
F27451
Fit the bevel gear crown (14) by using a hammer.
14
F29320
Apply Loctite 242 on the thread of the screws (1).
1
F27316
F27315
Copyright ©

ing.
13
F27460
F27318
Copyright ©
PINION GROUP
1
2
3
4
5
6
7
8
9
10
F27461
Disassembly
Position the differential carrier in a vise.

Unscrew the locknut (10) using special tool
380002218.
NOTE: this operation will irretrievably damage the

locknut (10).
10
F27462
Copyright ©
Remove the ring nut (10) and collect its retaining

washer (9).
9
10
F27463
Tap the shaft with a soft hammer to remove the bev-

el pinion (1). 8
SWARNING
Take care not to lower the bevel pinion (1).
5
Collect the washers (4) and (6), the collapsible 1
spacer (5) and the bearing (8).
6
4
F28106
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and 3
a hammer.
7
8
F28107
To remove the bearing (3) of the bevel pinion (1),

use a standard extractor.
Collect the bearing (3) and the underlying shim (2).
3
F27324
Copyright ©
Check all pinion components for wear.
SWARNING
The ring nut (10) and the collapsible spacer (5) must 5
be replaced when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8) using the special 3
drifts and a hammer.
7
8
F28107
Prepare the kit consisting of the special tools called

“false pinion” 380002219 and “false differential box”
380000407 + 380000440 and a depth gauge.
F28108
Insert the bearing (3) and (8) in their housings.

Assemble the “false pinion” 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the back-
lash is eliminated.
3
8
10
F28109
Copyright ©
Install “false differential box” special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
F28110
Assembly diagram of the “false differential box”

tools on the bearing differential support seats.
Use a depth gauge to measure distance “X” (dis- X
tance between the axis of the differential bearings
and the point at which the pinion head is supported,
or base of the bearing). X
F28111
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = request-
ed conical distance), from the measured value (X).
S = X-V mm
V
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
Copyright ©
Remove the “false differential box” special tool from

the differential supports (7).
Remove the ring nut (10), the “false pinion” and the
bearing (3) and (8).
3
8
10
F28109
Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special 3 5 6
tool 380002224 under a press, making sure that it is
well set.
2 4
Insert the shims (4) and (6) and a new collapsible
spacer (5).
1 1
NOTE: use always a new collapsible spacer (5).
F27334
Insert the bevel pinion (1) unit into the differential

support housing (7) and the bearing (8) into the pin- 8
ion shaft.
In order to force the bearing (8) into position, use the
It is advisable to offer resistance, for example a 5
sledge, to the beating force. 1
6
4
F28112
Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
9
10
F27463
Copyright ©
Screw the ring nut (10) in, using the wrench

380003218 for ring nut and for pinion retainer.
SWARNING
The torque setting is given by the preloading meas-
urement on bearings; tighten the ring nut (10) grad-
ually.
10
NOTE: if the tightening is excessive, the collapsible

spacer must be replaced and the procedure repeat-
ed. When you check the preloading, it is advisable F27445
to beat slightly both pinion ends with a soft hammer,

so as to help setting the bearings.
Carry out the preloading measurement P of the pin-

ion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
P = 9.2÷13.7 daN
(P = 20.7÷30.8 lbf)
SWARNING
F27432
All preloadings must be measured without the seal
ring.
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
Copyright ©
TOE-IN / STEERING ANGLE
1 2 3 3 2 1
5 5
4 4
F28113
Toe-in
Put two equal 1 m (3.3 ft) long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.
SWARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm 500 mm
F27340
Copyright ©
Measure the distance in mm (in) M between the

bars ends with a tapeline.
NOTE: keep the minimum value, swinging the

measurement point.
F27341
Check that the difference of the measurements be-

tween the wheel hubs diameters ends is within the
requested tolerance range. A -02
The nominal toe-in value (A) is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be relat-
ed to the ratio between length of the bar and flange
diameter:
0 0 A
nominal toe-in = A - 2 measured toe-in = M - 5
M -05
F27342
If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
1 3
tie rods (3) equally till the toe-in is within the request-
ed tolerance.
3 1
F27343
Copyright ©
After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
1 2
F27344
Steering angle adjustment
Use the same bars assembled for the toe-in adjust-

ment and a long bar perfectly leaned over the ma-
chined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.
F27345
Adjust a protractor to the requested angle and posi-

tion it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.
F27346
Adjust the mechanical steering stop, screwing in or

out the stop bolt (4), locking it with the locknut (5) to
the requested tightening torque.
5 4
F27347
Copyright ©
Steer completely towards the other side and repeat

the same operation.
F27348
Copyright ©
2.3 FAULT FINDING
PROBLEM CAUSE
1 2 3 4 5 6 7 8 9 10 11
Wheel vibration; front tyre resistance; half
shaft breakage
Steering is difficult; vehicle goes straight
while it’s turning
No differential action; jamming while
steering
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
1. Incorrect installation / defective axle

Correct installation or repair or replace the differential in case it does not survive any one of the test phases.
2. Overloading / incorrect weight distribution

Remove excessive weight and redistribute load, following instructions related to the vehicle.
3. Different rotation radius of the tyres

If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with bigger
radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both tyres.
4. Broken half shaft

It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.
5. Bent half shaft

Replace half shaft.
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all com-
ponents. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
7. Incorrect wheel adjustment

Verify group integrity and wheel side bearings.
Adjusting according.
8. Spoiled or worn out axle parts

Check the condition of ring gear, pinion gear, bearings etc.
Replace whenever necessary.
9. Contamination in the axle box or incorrect assembly of parts

Look for foreign particles. Check assembly of the various parts of the axle.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
11. Incorrect use of the product

See the vehicle producer’s instructions once again.
Copyright ©
PROBLEM CAUSE ACTION

Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set.
outer side the one foreseen Follow carefully the recommended
Incorrect gear adjustment operations for the adjustment of
(excessive backlash) bevel gear set backlash.
Pinion nut loose
Ring gear tooth broken side Load bump Replace bevel gear set.
Incorrect gear adjustment Follow carefully the recommended
(insufficient backlash) operations for the adjustment of
Pinion nut loose bevel gear set backlash.
Pinion or ring gear teeth worn Insufficient lubrication Replace bevel gear set.
Contaminated oil Follow carefully the recommended
Incorrect lubrication or depleted operations for the adjustment of
additives bevel gear set backlash.
Worn out pinion bearings that Use correct lubricants, fill up to the
cause an incorrect pinion axle right levels and replace according to
backlash and wrong contact the recommended program.
between pinion and ring
Overheated ring and pinion teeth Prolonged functioning at high Replace bevel gear set.
See if gear teeth have faded temperatures Use proper lubrication, fill up to right
Incorrect lubrication level and replace at recommended
Low oil level program.
Contaminated oil
Pinion teeth pitting Excessive use Replace bevel gear set.
Insufficient lubrication Use correct lubrication, fill up to the
right level and substitute at
recommended intervals.
Axle beam body bent Vehicle overloaded Replace axle beam body.
Vehicle’s accident
Load bump
Worn out or pitted bearings Insufficient lubrication Replace bearings.
Contaminated oil Use correct lubrication, fill up to the
Excessive use right level and replace at
Normal wear out recommended intervals.
Pinion nut loose
Oil leakage form gaskets and Prolonged functioning at high Replace the gasket or seal and
seals temperature of the oil matching surface if damaged.
Oil gasket assembled incorrectly Use correct lubrication and replace
Seal lip damaged at recommended intervals.
Contaminated oil
Excessive wearing out of input Exhaustive use Replace the flange.
flange spline Pinion nut loose Check that the pinion spline is not
Pinion axle backlash excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set.
See if the fracture line is well Continuous overload
defined
(wave lines, beach lines)
Pinion and ring teeth breakage Crash load of differential Check and/or replace other
components differential components.
Copyright ©
Side gear spline worn out Excessive use Replace differential gear group.
Replace all scratched washers Replace half shaft if required.
(Excessive backlash)
Thrust washer surface worn out Insufficient lubrication Use correct lubrication and fill up to
or scratched Incorrect lubrication right level.
Contaminated oil Replace at intervals recommended.
Replace all scratched washers and
those with 0,1 mm (0.004 in)
thickness lower than the new ones.
Inner diameter of tapered roller Excessive use Replace bearing.
bearing worn out Excessive pinion axial backlash Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right
Contaminated oil level and replace at recommended
intervals.
Bent or broken half shaft Vehicle intensively operated or Replace.
overloaded
Half shaft broken at wheel side Wheel support loose Replace.
Beam body bent Check that wheel support is not
worn out or wrongly adjusted.
Copyright ©
3. SPECIAL TOOLS
P/N CNH USE 4WD 4WS

380000406 Disassembly/assembly of differential ring nuts • •
380000407 + Calculation of pinion shims • •
380000440
380002213 Assembly of seal ring in the wheel hub / •
380002218 Disassembly/assembly of pinion rings • •
380002219 Calculation of pinion shims • •
380002222 Assembly of bearing cups in the wheel hub / •
380002223 Disassembly and assembly bushings in the crown retainer hub • /
380002224 Assembly of pinion bearing • •
380002225 Assembly of front flange seal connection / •
380002226 Assembly of bushing in the half beam / •
380002227 Assembly of seal ring in the wheel hub • /
380002432 Assembly of sliding block in the swivel housing • /
380002660 Assembly of bushing in the swivel housing • /
380002661 Assembly of seal ring in the swivel housing • /
380002662 Assembly of spherical joint on lower and upper king pin • /
380002663 Assembly of bearing cups in the wheel hub • /
380002664 Assembly of bushing in the seat of the upper king pin • /
380002665 Assembly of bushing in the half beam • /
380002666 Assembly of seal ring in the half beam • /
380002667 Disassembly/Assembly of bushings in the crown retainer hub / •
380002668 Assembly of bushing in the swivel housing / •
380002669 Assembly of seal ring in the swivel housing / •
380002670 Assembly of seal ring in the half beam / •

SM - 695SR - Tier3 - 6front Axles - EN

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM - 695SR - Tier3 - 6front Axles - EN

Uploaded by

Copyright:

Available Formats

Copyright ©

SECTION 25 - FRONT AXLES

1. FRONT AXLE 4WD “CARRARO” ................................................................................................................. 3

2 SECTION 25 - FRONT AXLES

SECTION 25 - FRONT AXLES 3

1. FRONT AXLE 4WD “CARRARO”

POWERSHIFT POWERSHUTTLE RATIO

4 SECTION 25 - FRONT AXLES

LUBRICATION AND GREASING

Differential oil capacity 6.5 litres (1.70 gal)

Fill in excess with MU/EP2 grease

Before assembling, grease indicated surface with POLYMER 400 grease

SECTION 25 - FRONT AXLES 5

6 SECTION 25 - FRONT AXLES

Drain all oil.

Always use the oil breather (2) to release possible

Before draining the oil from wheel end rotate the

SECTION 25 - FRONT AXLES 7

8 SECTION 25 - FRONT AXLES

80 Nm 25 Nm 120 Nm 8 Nm 300 Nm 120 Nm 169 Nm

SECTION 25 - FRONT AXLES 9

1.2 DISASSEMBLY AND ASSEMBLY

FRONT AND REAR SUPPORT

10 SECTION 25 - FRONT AXLES

Loosen the bolt (4).

NOTE: this is a destructive operation for the O-ring.

Remove the bolt (4).

Remove the bushes (6) from the rear support (5).

SECTION 25 - FRONT AXLES 11

Remove the cover (11) from differential support with

Remove the bush (9) and the thrust washer (10)

NOTE: it is advisable to heat the bush (9) to make

Loosen the bolt (19).

12 SECTION 25 - FRONT AXLES

Remove the bolt (19).

Remove the bush (17) and the thrust washer (16)

NOTE: it is advisable to heat the bush (17) to make

Insert the thrust washer (10) into the differential sup-

Assemble the seal ring (13) to the cover (11) with

SECTION 25 - FRONT AXLES 13

Assemble the cover (11) to the differential support.

Apply sealant on bushes (6) contact surface.

Assemble the bush (8) in the rear support (5).

Assemble the bolt (4).

Lubricate with grease a new O-ring (7).

14 SECTION 25 - FRONT AXLES

Insert the rear support (5) on the differential support.

Tighten the bolt (4) to the requested torque.

Assemble the flange (2) to the pinion shaft end (14).

Insert the thrust washer (16) into the front support

NOTE: if necessary assemble the bush (17) with a

Apply sealant on the bushes (21) contact surface.

SECTION 25 - FRONT AXLES 15

Assemble the bush (18) into the front support (20)

Assemble the bolt (19).

Insert the front support (20) on the axle beam.

16 SECTION 25 - FRONT AXLES

Loosen the nut (1) with enough turns till it is protrud-

NOTE: this is a destructive operation for the nut (1). 1

Repeat the whole sequence at the other side.

SECTION 25 - FRONT AXLES 17

Remove the cylinder head (15) from the cylinder

Assemble new seals and O-rings (13, 14, 16, 18, 20