JCB Drivetrain System 9803-9240 Service Manual

General Information 1
Care & Safety 2

Routine Maintenance 3
Hydraulics 4
Service Axles
5
Manual
JCB Drivetrain Systems Ltd
Wrexham Industrial Estate
Brakes
6
WREXHAM
United Kingdom
LL13 9UF
Tel: (01978) 661140 NOTE

Fax: (01978) 661863 All references in this manual to ‘Forward’ and
‘Reverse’ assume a front-mounted engine.
SD 55/NT AXLE
Publication No. 9803/9240
Issue 8
SD 55/NT Transmission Service Manual
Record of Changes
6th Update
Date Page Issue Changes
Sept 2003 Cover 7 Issue number raised.
1/3 - 1 3 Service Tool list Updated

1/4 - 1 2 Service Tool deleted
1/4 - 3 3 Service Tools Updated
1/4 - 4 1 New Page
1/4 - 5 1 New Page
3/1-1 2 SD40, SD55, SD70 No brakes added
3/ 4-1 2 All reference to Mobil oil deleted
5/Cont i 4 Drive Head Solid Spacer Assembly, Two Piece LSD Dismantling and Assembly, SD40,
SD70 Hub Dismantling and Assemble and Axle Hub bearing Removal Assembly added
5/1-1 4 SD40 AND SD70 Hub reduction added
5/2-1 3 Title changed
5/2-2 1 New Page
5/6-2 2 Step 6 changed, step 10 deleted
5/6-4 2 Note regarding Soild Spacer, step 6 and 13 torque setting added, step 11 backlash
changed
5/7-1 2 Gasket deleted from illustration
5/7-2 3 Collapsible Deleted, Note regarding Two Piece LSD
5/7-3 2 Gasket deleted from illustration
5/7-4 Addition to step 6, step 17 torque setting added
5/7-5 2 Note regarding Soild Spacer, Note regarding stake nut and washer
Step 12 rolling torque change. Step 15 backllash change.
5/7-8 to 7-12 1 New Pages
5/8-1 2 Note regarding stake nut, New assembly procedure
5/9-1 5 Dirt Shield added
5/9-2 5 Step 1 axle arm changed to axle stub, Step 3 pinon changed to gears. Note regarding
Hub Service Kit
5/9-4 3 Note regarding Hub Service Kit
5/9-10 2 Note regarding Hub Service Kit, Step 10 moved to after step 15 and steps renumbered,
Item 14 torque change
5/9-11 2 Item 14 torque change
5/10-1 to 10-5 1 New Pages
5/11-1 to 11-7 1 New pages
5/14-1 - 14-4 1 New pages
1
Record of Changes
5th Update

Dec 1998 Cover 6 Issue number raised.
1/Cont i 3 Axle Build Specification was Limited Slip Differential.
5/9-1 3 Blanking plugs Y and Z added to illustration.
5/9-2 4 Note regarding square seals removed. Note regarding excessive wear added.
5/9-3 4 Blanking plugs Y and Z added to illustration.
5/9-4 4 Notes added to items 16 and 18. Item 18 changed.
5/9-5 2 Note regarding Residual Pressure added. Note regarding square seals removed. Item 23
changed.
5/9-6 2 Information moved from 9-5.
5/9-7 2 Information moved from 9-6. Sealing plugs Y and Z added to illustration.
5/9-8 2 Information moved from 9-7. Note regarding excessive wear added to item 10.
5/9-9 2 Information moved from 9-8.
5/9-10 1 New page.
5/9-11 1 New page.
6/Cont i 2 Residual Brake System Pressure added. Brake seal or component leakage added.
6/2-1 2 Residual Brake System Pressure added. (Taken from 9803/3620 - 520-50 S/M).
6/3-1 1 New page.
6/3-2 1 New page.
1
Record of Changes
4th Update

Nov 1998 Cover 5 Issue number changed.
2/4-2 2 Warnings GEN-1-12 and GEN-1-13 added.
1
Record of Changes
3rd Update

Sept 1998 Cover 4 Issue number raised.
1/1-1 3 Axle Build Identification heading was Limited Slip Differential.
1
Record of Changes
2nd Update

April 1998 Cover 3 Issue number raised.
5/i 3 Items added for splined hub - Dismantling and Assembly.
5/1-1 3 General Description added. Brake type added.
5/9-1 3 Sub-heading changed.
5/9-2 3 Item 1 changed, note added, Sub-heading changed. Warning 5-3-2-1 added. Note to item
8 added.
5/9-5 3 Sub-heading changed. Item 20 was 17. Note to item 22 added.
5/9-6 1 New page.
5/9-7 1 New page.
5/9-8 1 New page.
5/9-9 1 New page.
1
Record of Changes
1st Update

August 1997 Cover 2 Issue number raised.
Intro 2 Item 6 Brakes added.
1/i 2 Limited Slip Differential added to contents.
1/1-1 2 Limited Slip Differential information added.
1/2-1 2 Grade 12.9 bolt list added.
1/3-1 2 Part numbers revised.
1/4-3 2 Service Tools added.
1/5-1 2 Part numbers revised.
3/i 2 Lubricants - Health and Safety added to contents.
3/1-1 2 Oil and grease specification revised.
3/1-2 1 New page - Lubricants - Health and Safety information added.
3/2-1 2 Service schedules revised.
3/3-1 2 Annotations corrected.
4/1-1 2 Valve pressures removed.
4/2-1 2 Note revised.
4/3-2 2 Grease and Sealant specification revised.
4/5-1 2 Item 3 corrected.
5/i 2 Contents titles revised and corrected.
5/1-1 2 Mounting and input items revised.
5/2-1 2 Illustration revised.
5/5-1 2 Grease specification revised.
5/6-2 2 Item 2 revised.
5/7-2 2 Note regarding friction plates added.
5/9-2 2 Items 2, 8, 10 and 14 revised. Items 20 to 23 added.
5/9-4 2 Item numbers revised.
5/9-5 2 Item numbers revised.
6/1-1 2 Friction plates revised from 3 to 2.
1
Introduction
This publication is designed for the benefit of Service Engineers.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants etc.
The remaining sections deal with Dismantling, Overhaul etc. of specific components:
4 = Hydraulics
5 = Axles
* 6 = Brakes
The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.
Section contents, technical data, operation descriptions etc. are inserted at the beginning of each section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section 6).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/9240 Issue 2*
Section 1 General Information Section 1
i i
Contents Page No.
Unit Identification 1-1
Replacement Parts 1-1
* Axle Build Identification 1-1
Torque Settings 2-1
Service Tools Numerical List 3-1
Service Tools 4-1
Sealing and Retaining Compounds 5-1
9803/9240 Issue 3*
1-1 1-1
Unit Identification
Axle Serial Plate (Offset Drive Head)
The axle serial number is stamped on a plate mounted on

the face of the axle, as shown.
ITL00990
* Axle Build Identification

Replacement Parts
To identify an axle build, the number on the axle data plate
1 When replacement parts are required, always ensure should be cross-referenced with the part number in the parts
that the correct parts are obtained, e.g. in the case of information.
gear replacements, always check the part number
stamped on the gear, and the number of teeth. Example:
2 When ordering replacement parts, quote the details on 450 / 2760 / 1 / 0091
the serial plate shown.
A B C
3 It is essential that all gaskets and seals removed while
dismantling, should be renewed on reassembly. A 450/2760: Axle assembly part number (450/27600)
without the final zeros.
4 On reassembly care should be taken that all parts are
/1: Internal issue number of the main manufacturing
correctly replaced since any component omitted or B
incorrectly assembled can lead to a complete failure. drawing.
5 Lubricants should comply with the recommended list C /0091: Axle serial number. The complete 12 digit number
as provided in this manual. It is important to adhere to must be quoted for warranty purposes. The parts
the oil changing procedure. information will detail the number of friction plates
required for the axle.
6 It is advisable to lightly lubricate with a recommended
lubricant, parts such as gears, shafts, thrust washers
and oil seals during reassembly.
9803/9240 Issue 4
2-1 2-1
Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
* Metric Grade 12.9 Bolts
Bolt Size Torque Settings

(mm) Nm kgf m lbf ft
M8 (8) 48 4.9 35
M10 (10) 94 9.6 69
M12 (12) 166 16.9 122
M14 (14) 320 32.6 236
M16 (16) 400 40.8 295
Note: All bolts are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/9240 Issue 2*
3-1 3-1
Service Tools Numerical List Page No.
* 445/12303 Washer 4-3

* 1315/3414Z Bolt M10 x 60 4-3
* 1315/3835Z Bolt M20 x 300 4-3
* 1370/0301Z Nut M10 4-3
* 1370/0401Z Nut M12 4-3
* 1370/0601Z Nut M16 4-3
* 1370/0701Z Nut M20 4-3
* 1315/3731Z Bolt M16 x 220 4-3
* 1420/0009Z Washer M12 4-3
* 1420/0012Z Washer M20 4-3
4003/0211 Anti-Seize Paste 5-1
4101/0251 Loctite 242 5-1
4101/0451 Loctite 932 5-1
4101/0651 Loctite 648 5-1
4101/0250 Loctite 243 5-1
4102/0551 Loctite 275 5-1
4102/1212 Loctite 574 or Permabond A136 5-1
4102/1951 Loctite 577 5-1
4104/0251 Activator (Aerosol) 5-1
4104/0253 Activator (Bottle) 5-1
4104/1557 Cleaner/Degreaser 5-1
892/00174 Measuring Cup - Pinion Head Bearing 4-2
892/00224 Impulse Extractor Set for Hub
Bearing Seals 4-2
* 892/00225 Adapter - Impulse Extractor 4-1
* 892/00286 Surface Temperature Probe 4-1
892/00333 Heavy Duty Socket 4-1
892/00334 Gland Seal Fitting Tool 4-1
892/00812 Drive Coupling Spanner 4-2
892/00822 Splined Bolt Socket 4-2
892/00833 Annulus Removal Tool 4-2
892/00891 Oil Seal Insertion Tool 4-3
* 921/52627 Spacer 14.20 Service use 4-5
* 921/53300 Spacer Kit- SD55 Axles 4-5
992/00800 Extractor for Removing Axle Pivot Pin 4-2
* 982/00918 Setting Tool Kit 4-5
* 892/01092 Hub Service Kit 4-3
* 917/02800 Bearing 4-3
* 992/04000 Torque Multiplier 4-2
* 993/70111 Breakback Torque Wrench 4-5
* 992/07601 Spanner for Half Shaft Nuts 4-1
* 993/99512 Spanner for Cylinder Piston Nut 4-1
* 997/11000 Support Bracket SD70, SD55 Front Axles4 - 5
* 998/10567 Pinion Shaft Adaptor 4-5
* 998/10623 Puller Beam 4-3
* 998/10606 Bearing Fitting Tube 4-3
* 998/10607 Inner Bearing Plate 4-3
* 998/10608 Bearing Centre Puller 4-3
* 998/10610 Puller Rod 4-3
* 998/10614 Reaction Tube 4-3
* 998/10615 Wheel Bearing Carrier Puller 4-3
* 998/10616 Puller Handle Nut 4-3
* 998/10624 Modified Wheel Stud 4-3
9803/9240 Issue 3*
4-1 4-1
Service Tools
JS07050
Cylinder Piston Nut removal/Fitting Spanner
993/99512 Spanner 55 mm A/F

993/99513 Spanner 60 mm A/F 892/00225 Adapter - Impulse Extractor
993/99514 Spanner 65 mm A/F Small 17 mm to 25 mm
993/99515 Spanner 70 mm A/F Medium 25 mm to 45 mm
Large 45 mm to 80 mm
892/00817 17 mm A/F x 3/4 in square drive

892/00333 19 mm A/F x 3/4 in square drive 892/00334 Gland Seal Fitting Tool
ITL01100
892/00286 Surface Temperature Probe
9803/9240 Issue 2*
4-2 4-2
Service Tools (cont'd)
992/04000
Torque Multiplier (use in conjunction with a torque wrench to give a

5:1 multiplication when tightening pinion nuts)
S197030
892/00822
Splined Bolt Socket for

driveshafts
892/00174
Measuring Cup - Pinion Head

Bearing S197060
S190770
S197070
892/00224
Impulse Extractor Set for Hub Bearing Seals 892/00833 Annulus Removal Tool
892/00812 Drive Coupling Spanner for axle

yoke couplings
992/00800 Extractor for removing axle pivot pin

S196720
9803/9240 Issue 1
4-3 4-3
*
Wheel Hub Service Tool -
A 5
A Bearing Puller
B Bearing Press
C Hub Seal Dolly 1
Item Description Part No. Qty
6
A, B & C Hub Service Kit 892/01092 1
comprises of: 8,9
1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1 7
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2 2
5 Reaction Tube 998/10614 1
6 ModifiedWheel Stud 998/10624 2
7 Wheel Bearing Carrier
Puller 998/10615 2 10
8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2 4 11,12
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1 3
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
21 Seal Dolly 892/00891 1
15
B 13
16
14
18 19, 20
8
C 21
17
A439160
9803/9240 Issue 3*
4-4 4-4
1
5
A396940
A396950
A396930
9803/9240 Issue 1*
4-5 4-5
Solid Spacer Setting Kit
1 892/00918 Setting Tool Kit

2 921/52627 Spacer 14.20 Service use
3 993/70111 Breakback Torque Wrench
4 997/11000 Support Bracket
SD55, SD70 Front Axles
7 998/10567 Pinion Shaft Adaptor
6 921/53300 Spacer Kit - SD55 Axles
Comprises of:
Spacer thickness mm
921/53322 13.550 S261230
921/53323 13.575
921/53324 13.600
921/53325 13.625
921/53301 13.650 Torque Measuring Tool for Wheel Hub Seals
921/53302 13.675
921/53303 13.700 Manufacture locally, procedures in this manual show
921/53304 13.725 checking the wheel hub seal using a rolling force.
921/53305 13.750 However, the torque can be measured using above
921/53306 13.775 locally manufactured tool.
921/53307 13.800
921/53308 13.825 Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft)
921/53309 13.850 excluding seal drag. Maximum permissible including
921/53310 13.875 seal drag is 40 Nm (29.5 lbf ft).
921/53311 13.900
921/53312 13.925
921/53313 13.950
921/53314 13.975
921/53315 14.000
921/53316 14.025
921/53317 14.050
921/53318 14.075
921/53319 14.100
921/53320 14.125
921/53321 14.150
9803/9240 Issue 1*
5-1 5-1
* Sealing and Retaining Compounds
Loctite 574 or A medium strength sealant suitable for all

Permabond A136 sizes of gasket flanges, and for hydraulic
fittings of 25-65 mm diameter. 4102/1212
Loctite 275 or For all size of flanges where the strength

Permabond A140 of the joint is important. 4102/0551
Loctite 932 or For all retaining parts which are likely to

Permabond A137 be dismantled and for use on threads larger
than 50 mm dia. † 4101/0451
Loctite 242 or A medium strength locking fluid for sealing

Permabond A113 and retaining nuts, bolts, and screws up to
50mm diameter, and for hydraulic fittings
up to 25 mm diameter. † 4101/0251
Loctite 243 A medium strength locking fluid similar

to Loctite 242 but with greater resistance
to thread contamination. 4101/0250
Loctite 648 or For retaining parts which are unlikely

Permabond A118 to be dismantled. 4101/0651
Loctite 577 A medium strength thread sealing compound. 4102/1951
Loctite Activator A cleaning primer which speeds the curing † 4104/0251 Aerosol
rate of anaerobic products. † 4104/0253 Bottle
Cleaner/Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. † 4104/1557 Aerosol
Anti-Seize Paste A compound used for assembly and prevention

of thread seizure. † 4003/0211
Note: The above list is the range of sealants and retaining compounds available. Items marked † are those referred to within
the sections.
9803/9240 Issue 2*
Section 2 Care & Safety Section 2
i i
Contents Page No.

Safety Notices 1-1
General safety 2-1
Operating safety 3-1
Maintenance safety 4-1
9803/9240 Issue 1
1-1 1-1
Safety Notices
In this publication and on the machine, there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly
probable that the operator (or others) could be killed or seriously injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others)
could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could
result in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/9240 Issue 1
2-1 2-1
All machinery, whether mobile or static, can be hazardous.

When equipment is correctly operated and properly
maintained it can be safe to work with. But when it is
carelessly operated or poorly maintained it can become a
danger.
Do not work with any equipment until you are sure that it is
serviceable, that you know how to control it and be aware of
all relevant safety requirements.
If the equipment covered by this manual forms part of a

larger product (eg. a vehicle) be sure to observe the safety
requirements which relate to the product as a whole, as well
as those given in this manual.
On this and the following pages and throughout this manual,

you will find safety messages. Please read and understand
these safety messages before using and working on the
equipment covered in this manual.
Make sure you also read and understand all other safety
messages contained in operator handbooks and service
manuals concerned with the product of which this
equipment forms part.
Remember
BE CAREFUL
BE ALERT
BE SAFE
General Safety
! WARNING
Decals ! WARNING
This equipment may include safety decals Lifting Equipment
You can be injured if you do not obey decal safety You can be injured if you use faulty lifting equipment. Make
instructions. Keep decals clean. Replace unreadable or sure that lifting equipment is in good condition. Make sure
missing decals with new ones before operating the that lifting tackle complies with all local regulations and is
equipment. Make sure replacement parts include warning suitable for the job. Make sure that lifting equipment is
decals where necessary. strong enough for the job.
INT-1-3-7
! WARNING
Clothing ! WARNING
You can be injured if you do not wear the proper clothing. Raised Attachments
Loose clothing can get caught in the equipment. Wear Raised attachments on certain kinds of equipment can fall
protective clothing to suit the job. Examples of protective and injure you. Do not walk or work under raised
clothing are: a hard hat, safety shoes, safety glasses, a well attachments unless they are safely blocked.
fitting overall, ear-protectors and industrial gloves. Keep INT-1-3-8
cuffs fastened. Do not wear a necktie or scarf. Keep long

hair restrained. ! WARNING
Care and Alertness
! WARNING All the time you are working with or on the equipment, take
Alcohol and Drugs care and stay alert. Always be careful. Always be alert for
It is extremely dangerous to operate machinery when under hazards.
the influence of alcohol or drugs. Do not consume alcoholic
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
9803/9240 Issue 1
3-1 3-1
Operating Safety
! WARNING ! WARNING
Equipment Condition Communications
Defective equipment can injure you or others. Do not Bad communications can cause accidents. Keep people
operate equipment which is defective or has missing parts. around you informed of what you will be doing. If you will be
Make sure all maintenance procedures are completed working with other people, make sure any hand signals that
before using the equipment. may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
! WARNING
Controls ! WARNING
You or others can be killed or seriously injured if you operate The transmission can be in 4 wheel drive until de-selected
machine control levers from outside the cab. Operate the by hydraulic pressure to 2 wheel drive. If the machine is to
control levers only when you are correctly seated inside the be raised and the engine/transmission run, make sure all
cab. four wheels are off the ground and supported by axle
stands. If only the rear wheels are raised, the machine could
still drive through the front axle.
! WARNING
Equipment Limits
Operating equipment beyond its design limits can damage
the equipment, it can also be dangerous. Do not operate the
equipment outside its limits. Do not try to upgrade the
equipment performance with unapproved modifications.
! WARNING
Engine/Steering Failure
If the engine or steering on the ‘parent’ machine fails, stop
the machine as quickly as possible. Do not operate the
machine until the fault has been corrected.
! WARNING
Engine
The engine on the ‘parent’ machine has rotating parts. Do
not open the engine cover while the engine is running. Do
not use the machine with the cover open.
! DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
! WARNING
Exhaust Gases
Breathing the ’parent’ machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
9803/9240 Issue 1
4-1 4-1
Maintenance Safety
! WARNING ! DANGER
Repairs Hydraulic Pressure
Do not try to do repairs or any other type of maintenance Hydraulic fluid at system pressure can injure you. Before
work you do not understand. To avoid injury and/or damage disconnecting or connecting hydraulic hoses, stop the
get the work done by a specialist engineer. engine and operate the controls to release pressure trapped
GEN-1-5
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/1
! WARNING
Modifications and Welding
Non-approved modifications can cause injury and damage. ! WARNING
Welds on cast iron can weaken the structure and break. Do Oil
not weld cast iron. Contact your distributor for advice before Oil is toxic. If you swallow any oil, do not induce vomiting,
modifying the equipment. seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
! WARNING cream or wear gloves to prevent skin contact. Wash skin
Metal Splinters contaminated with oil thoroughly in warm soapy water. Do
You can be injured by flying metal splinters when driving not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
! WARNING
Soft Ground
! WARNING A machine can sink into soft ground. Never work under a
Electrical Circuits machine on soft ground.
INT-3-2-4
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4 ! WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
! WARNING will protect against eye injury from components accidently
Battery Gases flying out.
GEN 6-2
Batteries give off explosive gases. Keep flames and sparks
away from the vehicle battery. Do not smoke close to the
battery. Make sure there is good ventilation in closed areas
where batteries are being used or charged. Do not check the ! CAUTION
battery charge by shorting the terminals with metal; use a Cleaning
hydrometer or voltmeter. Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
! WARNING
Hydraulic Fluid ! CAUTION
Fine jets of hydraulic fluid at high pressure can penetrate the
'O' rings, Seals and Gaskets
skin. Do not use your fingers to check for hydraulic fluid
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
leaks. Do not put your face close to suspected leaks. Hold a
can cause leakages and possible accidents. Renew
piece of cardboard close to suspected leaks and then
whenever disturbed unless otherwise instructed. Do not use
inspect the cardboard for signs of hydraulic fluid. If hydraulic
Triochloroethane or paint thinners near 'O' rings and seals.
fluid penetrates your skin, get medical help immediately. INT-3-2-12
INT-3-1-10/1
9803/9240 Issue 1
4-2 4-2
Maintenance Safety (cont'd)
! WARNING ! WARNING
Fires Fluoroelastomeric Materials
Do not use water to put out an equipment fire, you could Certain seals and gaskets (e.g. transmission oil seals) may
spread an oil fire or get a shock from an elecrical fire. Use contain fluoroelastomeric materials such as Viton, Fluorel
carbon dioxide, dry chemical or foam extinguishers. Contact and Technoflon. Fluoroelastomeric materials subjected to
your nearest fire department as quickly as possible. high temperatures can produce highly corrosive hydrofluoric
Firefighters should use self-contained breathing apparatus. acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature

! WARNING require no special safety precautions.
Jacking
A machine can roll off jacks and crush you unless the wheels Used fluoroelastomeric components whose temperatures
have been chocked. Always chock the wheels at the have not exceeded 300°C require no special safety
opposite end of the machine that is to be jacked. Do not precautions. If evidence of decomposition (e.g. charring) is
work underneath a machine supported only by jacks. Always found, refer to the next paragraph for safety instructions DO
support a jacked-up machine on axle stands before working NOT TOUCH COMPONENT OR SURROUNDING AREA.
underneath it.
INT-3-2-8
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (e.g. engine fire) must be
! WARNING treated using the following safety procedure. Make sure that
Hydraulic Hoses heavy duty gloves and special safety glasses are worn:
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for: 1 Ensure that components have cooled then remove and
- Damaged end fittings place material into plastic bags.
- Chafed outer covers
- Ballooned outer covers 2 Thoroughly wash contaminated area with 10% calcium
- Kinked or crushed hoses hydroxide or other suitable alkali solution, if necessary
- Embedded armouring in outer covers use wire wool to remove burnt remains.
- Displaced end fittings.
INT-3-3-2 3 Thoroughly wash contaminated area with detergent and
water.
! WARNING
4 Contain all removed material, gloves etc. used in this
Make the machine safe before working underneath it. Park operation in sealed plastic bags and dispose of in
the machine on level ground. Apply the parking brake, put accordance with Local Authority Regulations.
the transmission in neutral and stop the engine. Chock both
sides of all four wheels. DO NOT BURN FLUOROELASTOMERIC MATERIALS.
Disconnect the battery, to prevent the engine being started If contamination of skin or eyes occurs, wash the affected
while you are beneath the machine. area with a continuous supply of clean water or with calcium
GEN-1-2/IT
hydroxide solution for 15-60 minutes. Get medical attention
immediately.
! WARNING INT-3-3-5/1/IT
To avoid burning, wear protective gloves when handling hot

components. To protect your eyes, wear goggles when
* ! WARNING
using a wire brush to clean components. Protect your eyes when grinding metal. Wear safety glasses
HYD 1-3
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
! WARNING GEN-1-12
Some lubricants contain lead. The repeated swallowing of

very small quantities can cause chronic lead poisoning. Do ! WARNING
not smoke or touch food while handling this lubricant. *
Before carrying out any servicing, park the machine on firm
Dispose of waste (rags etc.) in accordance with local level ground and apply the parking brake. Make sure the
regulations. transmission selector and gear lever are in the neutral
2-1-1-8/IT
position. Switch OFF the engine and remove the starter key.
Operate the control levers and remove the hydraulic filler
cap to vent any residual pressure. Disconnect the battery.
GEN-1 13
9803/9240 Issue 2*
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Lubricants & Capacities 1-1
* Lubricants - Health and Safety 1-2
Service Schedules 2-1
Greasing
- Axle 3-1
Axle Oil Level

- Check Differential Oil Level 4-1
- Change Differential Oil 4-1
- Check Hub Oil Level 4-1
- Change Hub Oil 4-1
9803/9240 Issue 2*
1-1 1-1
Lubricants & Capacities

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
Litres UK Gals SPECIFICATION
Axle - SD55/NT API GL4, M2C41B/134D,

Housing 8.0 1.76 Q8 EL3857 / Mobil Fluid 424 F M1135/M1141/M1143
Hubs (x2)
SD55 (Brakes) 2.0 0.44 Q8 EL3857 SAE90 / Mobil Fluid 424 API GL4, M2C41B/134D,
MF M1135/M1141/M1143
* SD40 (No Brakes) 1.0 0.22 Q8 T35 SAE90 / Mobilube HD90 API-GL5, MIL-L2105C
* SD55 (No Brakes) 1.8 0.40
* SD70 (No Brakes) 2.0 0.44
Grease Points - - Mobil HP222 Mobil HP222
Brake System - - Mobil DTE 11M ISO VG 15

CAUTION: Do not use ordinary
brake fluid (J1703)
Note 1: Q8 EL3857 / Mobil 424 should always be used for axles fitted with brakes. For axles without brakes Q8 T35 SAE90 /
Mobilube HD90 or Q8 EL3857 / Mobil Fluid 424 can be used.
Note 2: For axles with limited slip differential, Q8 EL3857 / Mobil Fluid 424 must be used.
9803/9240 Issue 2*
1-2 Lubricants - Health and Safety 1-2
Hygiene
Lubricants are not a health risk when used properly for their 2 Apply a barrier cream to the skin before handling used
intended purposes. oil.
However, excessive or prolonged skin contact can remove 3 Note the following when removing oil from skin:
the natural fats from your skin, causing dryness and
irritation. a Wash your skin thoroughly with soap and water.
Low viscosity oils are more likely to do this, so take special b Using a nail brush will help.
care when handling used oils, which might be diluted with
fuel contamination. c Use special hand cleansers to help clean dirty
hands.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For d Never use petrol, diesel fuel, or paraffin for washing.
details of these precautions we advise you to read the
relevant publications issued by your local health authority, 4 Avoid skin contact with oil soaked clothing.
plus the following.
5 Don't keep oily rags in pockets.
Storage
6 Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children.
7 Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers.
First Aid - Oil
Waste Disposal
Eyes
All waste products should be disposed of in accordance In the case of eye contact, flush with water for 15 minutes. If
with all the relevant regulations. irritation persists, get medical attention.
The collection and disposal of used oil should be in Swallowing

accordance with any local regulations. Never pour used oil If oil is swallowed do not induce vomiting. Get medical
into sewers, drains or on the ground. advice.
Skin
Handling In the case of excessive skin contact, wash with soap and
water.
New Oil
There are no special precautions needed for the handling or

Spillage
use of new oil, beside the normal care and hygiene
practices. Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
Used Oil area.
Used lubricants contain harmful contaminants. Fires

Here are precautions to protect your health when handling Extinguish with carbon dioxide, dry chemical or foam. Fire-
used oil: fighters should use self-contained breathing apparatus.
1 Avoid prolonged, excessive or repeated skin contact

with used oils.
9803/9240 Issue 1
2-1 2-1
Service Schedules
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working
condition.
! WARNING
A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one
end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the
machine when working under it.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
GEN-1-1
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings
to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the
regular maintenance checks are rectified immediately.
Calendar equivalents:
10 Hours = Daily
50 Hours = Weekly
500 Hours = Six Months
1000 Hours = Yearly
2000 Hours = 2 Years
Service checks should be carried out as in the table at whichever time occurs first.
*
Pre-start Cold Checks Operation 10 50 †100 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
AXLES AND STEERING

Axle Oil Level (incl. Hubs when applicable) - Check G G G G
Axle Oil (incl. Hubs when applicable) - Change G G G G
Drive Shafts - Security/Grease G G G
Steer Axle Movement/Shimming - Check G G G G
Axle Pivot and Steering Joints †† - Grease G G G G

*
HYDRAULICS
Cylinders - Chrome Condition - Check G G G
Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr
AXLES AND STEERING

Steering Modes - Operation - Check G G G G G G
Wheel Nut Torque - Check G G G G G G
Steer Phasing - Check G G G
Steer Cylinders - Balance - Check G G G G
Steer Circuit Pressure - Check G G G G
† Note: First 100 Hours Service only, to be completed by your Distributor.
†† Note: Mobil HP222 Grease must be used at 500 hour intervals. If an alternative grease is used, the Service Interval must
* be reduced to 50 hours/weekly.
Note: Check for leaks every 50 hours, check level if leaking.
Note: Jobs which should only be done by a specialist are indicated by a .
Note: Check generally for leaks on ALL systems, for example, hydraulics, axles etc. If a leak is evident find the source
and repair as required. Make sure that the system is topped up with the recommended fluid after repair.
Note: Faults in the braking system must be rectified immediately. Ensure the correct brake fluid is used (see
*
Lubricants and Capacities), and all equipment is clean and free from water contamination. Under no circumstances
should water be allowed to enter the braking system.
9803/9240 Issue 2*
3-1 3-1
Greasing
SD55/NT Axles - Offset Drive Head

- for Interval see Service Schedule
Total 10 Grease Points
Note: When greasing, raise the wheels and swing them from
lock to lock. This will ensure full penetration.
3 1 5
4 6
0
7 9
9803/9240 Issue 2*
4-1 4-1
Axle Oil Level

Check Differential Oil Level - for Interval see Service Change Hub Oil - for Interval see Service Schedule
Schedule
1 Set the machine level, with the tyres just clear of the
1 Remove fill/level plug A and its bonded washer. Oil ground. Manually rotate the wheels to bring the OIL
should be level with the bottom of the fill/level hole. LEVEL mark on the hubs to the vertical position, with
the fill/level plugs C at the bottom.
2 If necessary, top up oil as specified in Lubricants and
Capacities, on page 3/1-1. Clean and refit fill/level plug
A with new bonded washer.
Change Differential Oil - for Intervals see Service Schedule
1 Remove fill/level plug A and drain plug B, together with

their bonded washers. Allow time for the oil to drain
out.
2 Clean and refit drain plug B with a new bonded washer.

Tighten to 79 Nm (58 lbf ft).
LEVEL
OIL
3 Fill the axle with oil, as specified in Lubricants and C
Capacities, on page 3/1-1, through the fill/level hole A.
Oil should be level with the bottom of the fill/level hole.
4 Clean and refit fill/level plug A with a new bonded

washer.
ITL00710
2 Remove fill/level plugs C. Allow time for the oil to drain

out.
3 Set OIL LEVEL marks to the horizontal.
B
OIL
LEVEL
ITL00700 C
Check Hub Oil Level - for Interval see Service Schedule
1 Make sure the OIL LEVEL mark on the hub is

horizontal.
ITL00710
2 Remove fill/level plug C. Oil should be level with the

bottom of the fill/level hole. 4 Fill the hubs with oil, as specified in Lubricants and
Capacities, on page 3/1-1, through the fill/level holes
3 If necessary, top up with oil as specified in Lubricants C. Oil should be level with the bottom of the fill/level
and Capacities, on page 3/1-1. Clean and refit fill/level hole.
plug C.
5 Clean and are fit fill/level plugs C.
9803/9240 Issue 2*
Section 4 Hydraulics Section 4
i i
Contents Page No.
Technical Data 1-1
Cylinders
Steer Cylinder
- Removal and Replacement 2-1
- Dismantling and Assembly 3-1
Steering System - Bleeding Procedure 4-1
Gland Seal Fitting Procedure 5-1
9803/9240 Issue 1
1-1 Technical Data 1-1
Steering
* Relief Valve Pressure @ 1500 rpm Refer to Machine Operator Handbook

* Shock Valve Pressure Refer to Machine Operator Handbook
JCB Drivetrain Steer Cylinder Data

Torque Settings
Piston Head 300 Nm 30.6 kgf m 221 lbf ft

End Cap 450 Nm 45.9 kgf m 332 lbf ft
Sizes
Bore Diameter 60 mm (2.36 in)

Rod Diameter 30 mm (1.18 in)
Note: The above data refers to JCB Drivetrain Steer Cylinders, please check the type of cylinder fitted before using this
section. For different cylinders refer to original manufacturer’s data.
9803/9240 Issue 3
2-1 2-1
Steer Cylinder
Removal and Replacement
This procedure is for a typical steering cylinder removal and

replacement.
! WARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it.
Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-1-1
Removal
B
Disconnect and cap hydraulic hoses to prevent loss of fluid
and ingress of dirt. Label hoses for identification and correct
refitting.
Remove locking bolts A and pivot pins B.
Remove steering cylinder from machine.
Replacement
Replace steering cylinder by reversing the removal

procedure.
Apply anti-seize paste, part number 4003/0211 to pivot pins

B, to facilitate subsequent removal.
After connecting hoses check hydraulic fluid level, if

necessary top up.
A
* Bleed hydraulic steering system (see Steering System -
Bleeding Procedure).
ITL00 ITL00580
0
9803/9240 Issue 2*
3-1 3-1
Steer Cylinder
Dismantling and Assembly
147640
9803/9240 Issue 1
3-2 3-2
Steer Cylinder (cont’d)

Dismantling and Assembly (cont’d) Assembling
The numerical sequence shown on the illustration is Clean threads of piston rod, piston head, end cap and
intended as a guide to dismantling. cylinder using a wire brush.
For assembly the sequence should be reversed. * Use Loctite Cleaner/Degreaser to ensure that all threads are
free from grease, hydraulic oil and old Loctite. Allow 15
Dismantling minutes for solvent to dry before applying Loctite.
Place cylinder assembly on a locally manufactured Ensure that lubricants used during assembly do not come
strip/rebuild bench as shown. into contact with Loctite.
Slacken end cap 1 using special spanner (see Service Refer to the ‘Gland Seal Fitting Procedure’ on page 4/5 - 1.
Tools, Section 1) and remove the piston rod assembly 2 Fit seals 10 and 11 into end cap then fit the end cap onto
from the cylinder. the piston rod.
! WARNING * Apply Loctite Activator to threads of piston rod, end cap and
cylinder. Allow Activator to dry for 15 minutes before
If air or hydraulic pressure is used to force out the piston
bringing into contact with Loctite.
assembly, ensure that the end cap is securely fitted.
Severe injury can be caused by a suddenly released
Note: Neither Loctite nor Activator must be allowed to
piston rod.
HYD 1-2 contact seals, bearing rings, or ‘O’ rings.
Position piston rod assembly on bench in place of cylinder. * Apply Loctite 262 to all threads of piston rod. Renew ‘’O’
Remove seal and wear rings from piston head. ring in piston head, lubricating only the ‘O’ ring with Mobil
HP222 Grease. Fit and torque tighten the piston head. Fit a
Remove locking ring 3. new locking ring 3.
Heat piston head to 180 - 210 °C to degrade the Loctite Fit new seal and wear rings to piston head.
between piston head and rod. To check temperature, use
Surface Temperature Probe (see Service Tools, Section 1). Position cylinder on bench and install rod assembly into
cylinder.
CAUTION: Do not exceed 300 °C or the Loctite will char,
causing thread pick-up. Apply Loctite 932 to thread of end cap, fit a new ‘O’ ring 9
and torque tighten the end cap into the cylinder.
! WARNING
To avoid burning, wear protective gloves when handling Note: If hydraulic oil contacts uncured Loctite a weakening
hot components. To protect your eyes, wear goggles of the bond will result. Cure times vary according to the
when using a wire brush to clean components. ambient temperature and type of Activator used. The
HYD 1-3 following approximate cure time applies at 20 °C and is the
minimum period between assembly and filling the cylinder
Remove piston head from rod using special spanner (see
with oil.
Service Tools, Section 1).
*
Loctite 262 or 932 with Activator - 1 hour
Remove end cap from piston rod and remove the seals and
‘O’ ring.
Torque Settings
Ensure that metal components are free from scoring, nicks
Item Nm kgf m lbf ft
and burrs. A damaged rod will impair the life of the gland
7 405 41.3 300
seal.
1 678 69.2 500
Note: Cold weather operation. When operating in conditions

which are consistently below freezing, it is recommended
that the cylinders are operated slowly to their full extent
before commencing normal working.
9803/9240 Issue 2*
4-1 4-1
Steering System - Bleeding Procedure

Whenever any hydraulic steering component is
disconnected or removed the system must be bled as
follows:
With the engine running, this procedure must be carried out

in the correct order that is laid down. You must not alter the
order of selections and operations.
1 Select 2 Wheel Steer
a Turn steering wheel to left, until front wheels are

fully locked to the left.
b Turn steering wheel to right, until front wheels are
fully locked to the right.

a Turn steering wheel to full right lock.

b Turn steering wheel to full left lock.
c Turn steering wheel to full right lock.
a Turn steering wheel to left, until the front wheels are




a Turn steering wheel to left, until the front and rear

wheels are fully locked.
9803/9240 Issue 1
5-1 5-1
Gland Seal Fitting Procedure

The size (diameter) and position of pins A is determined by
the diameter and radial width of the gland seal being fitted.
The pins are screwed into threaded holes in the tool body,
the spacing of the holes are designed to suit small or large
diameter gland seals.
To fit a new gland seal:
1 Open the tool as shown at X and insert the new gland

seal, the seal must be fitted behind the two front pins
X
but in front of the rear pin as shown.
161750-X
2 Close the tool as shown at Y. The seal must form a

reniform (kidney shape).
Y
161750-Y
*3 Locate the seal in the end cap groove, shown at Z,

when the seal is in position, open the tool to release the
Z
seal. Make sure the seal is correctly installed in its
groove and remove the tool.
9803/9240 Issue 2*
Section 5 Axles Section 5
i i
Contents Page No.
Technical Data
SD55/NT Axle 1-1
Descriptions
Cutaway of SD55/NT Axle 2-1
SD55/NT Axle - Pin Mounted

Removal and Replacement 3-1
SD55/NT Axle - Pad Mounted

Removal and Replacement 4-1
SD55/NT Axle
Propshafts - Removal and Replacement 5-1
Drive Head - Dismantling 6-1
Drive Head - Assembly 6-2
Drive Head with Limited Slip differential - Dismantling 7 - 1
Drive Head with Limited Slip Differential - Assembly 7-3
* Drive Head Solid Spacer - Assembly 7-8
* Two Piece Limited Slip Differential - Dismantling 7 - 11
* Two Piece Limited Slip Differential - Assembly 7 - 11
Renewing the Pinion Oil Seal 8-1
Axle Hub and Driveshaft (Dowelled)
- 2 Plate, Positive Retraction Brakes - Dismantling 9-1
Axle Hub and Driveshaft (Dowelled)
- 2 Plate, Positive Retraction Brakes - Assembly 9-3
Axle Hub and Driveshaft (Splined)
- 2 Plate, Positive Retraction Brakes - Dismantling 9-6
Axle Hub and Driveshaft (Splined)
- 2 Plate, Positive Retraction Brakes - Assembly 9-8
* Axle Hub and Driveshaft (Splined)
- SD40 Non Braked Hub - Dismantling 10 - 1
* Axle Hub and Driveshaft (Splined)
- SD40 Non Braked Hub - Assembly 10 - 3
* Axle Hub and Driveshaft (Dowelled)
- SD70 Non Braked Hub - Dismantling 11 - 1
* Axle Hub and Driveshaft (Dowelled)
- SD70 Non Braked Hub - Assembly 11 - 3
* Axle Hub Bearing - Removal 14 - 1
* Axle Hub Bearing - Replacement 14 - 3
9803/9240 Issue 4*
SD 55/NT Axle
Type JCB Drivetrain spiral bevel input with epicyclic hub reduction.
Designation SD55/NT
* Type of Brakes Oil immersed multi-plate disc located in hubs.
Installation Centre pivot or rigid pad mount
Number of steer cylinders 1
Weight
(dry, with no steer cylinders and
without wheels) Pin: 367 kg (809 lb) approximately; Pad: 365 kg (805 lb) approximately
Ratios OPTION 1 OPTION 2 OPTION 3 OPTION 4 OPTION 5 OPTION 6 OPTION 7

Overall 10.46:1 12.24:1 16.2:1 18.6:1 19.2:1 20.93:1 23.625:1
Crownwheel and Pinion 1.94:1 2.26:1 3.0:1 3.44:1 3.55:1 3.875:1 4.375
Number of Teeth
Crownwheel 31 34 33 31 32 31 35
Pinion 16 15 11 9 9 8 8
* Hub Reduction 5.4:1
6.0:1 (SD40 and SD70 hubs only)
Input Type 1480 Half yoke
Toe-in 0°
Castor Angle 0°
Camber Angle 1°
Kingpin inclination 0°
General Description
The later type SD55/NT axles have changed from ring dowel and Verbus Ripp bolt securing of the annulus carrier to the hub
swivel to a splined annulus carrier and hub swivel with retaining plate. For Dismantling and Assembly procedures see pages 9 -
6 to 9 - 9.
9803/9240 Issue 5
2-1 Descriptions 2-1
* SD 55/NT Axle with Braked Hub (Dowelled)

(Steering cylinder not shown)
ITL007 0
9803/9240 Issue 3*
SD 55/NT Axle with Non Braked Hub

(Dowelled)
(Steering cylinder not shown)
9803/9220 Issue 1*
3-1 SD 55/NT Axle - Pin Mounted 3-1
E D
A F
C
B
9803/9240 Issue 1
3-2 SD 55/NT Axle - Pin Mounted 3-2
! WARNING

GEN-1-1
Removal Replacement
1 Using Tool No. 892/00822 remove bolts A to Replacement is the reverse of the removal sequence.
disconnect the propshaft from the axle (refer to Page 3
- 1). 1 Apply Loctite 242 to the threads of bolts A.
2 Disconnect the brake pipes from the axle swivel hubs, 2 Whenever a wheel has been removed, check the wheel
blank off the exposed connections. nut torques every two hours until they stay correct.
3 Disconnect the hydraulic pipes from the steer cylinder,
blank off all exposed connections.
! WARNING
If, for whatever reason, a wheel stud is renewed, all the
4 Loosen the road wheel retaining nuts B. studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.
2-3-2-8
5 Make sure that the wheels are blocked. Raise the
machine and engage the parking brake if appropriate.
Torque Settings
6 Prop the machine on each side as shown at C.
A 40-48 4.08-4.90 29.5-35.4
7 Remove the road wheels.
B 680 69 500
8 Position a jack underneath the balance point (see Note)
of the axle and support the axle weight.
Note: Because the drive head assembly is offset, the

balance point of the axle is not the centre of the axle. Attach
a ‘cradle’ to the jack that will partially embrace the axle.
9 Remove nut D and pivot pin retaining bolt E.
10 Use puller (tool no. 992/08800) and remove the pivot

pin F.
11 Lower the jack so that the axle is clear of the mounting

yoke and remove the axle.
9803/9240 Issue 1
4-1 SD 55/NT Axle - Pad Mounted 4-1
F
D
9803/9240 Issue 1
4-2 SD 55/NT Axle - Pad Mounted 4-2
! WARNING

GEN-1-1
Removal Replacement
1 Using Tool No. 892/00822 remove bolts A to Replacement is the reverse of the removal sequence.
disconnect the propshaft from the axle (refer to Page 4
- 1). 1 Apply Loctite 242 to the threads of bolts A.
2 Disconnect the brake pipes from the axle swivel hubs, 2 Whenever a wheel has been removed, check the wheel
blank off the exposed connections. nut torques every two hours until they stay correct.
3 Disconnect the hydraulic pipes from the steer cylinder,
blank off all exposed connections.
! WARNING
If, for whatever reason, a wheel stud is renewed, all the
4 Loosen the road wheel retaining nuts B. studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.
2-3-2-8
5 Make sure that the wheels are blocked. Raise the
machine and engage the parking brake if appropriate.
! CAUTION
6 Prop the machine on each side as shown at C. Bleed the brake system before driving the machine.
BRAK 1-6
7 Remove the road wheels.
Torque Settings
8 Position a jack underneath the balance point (see Note)
of the axle and support the axle weight. Item Nm kgf m lbf ft
A 20.9-23.7 2.13-2.42 15.4-17.5
Note: Because the drive head assembly is offset, the B 680 69 500
balance point of the axle is not the centre of the axle. Attach D 476 49 351
a ‘cradle’ to the jack that will partially embrace the axle.
9 Remove nut D, bolts E and washers F.
10 Lower the jack and remove the axle.
9803/9240 Issue 1
5-1 SD 55/NT Axle 5-1
Propshafts
Removal
Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.
* Replacement
Upon reassembly, after lubricating sliding joints with Mobil

HP222 Grease, align the shafts against identification marks
previously made or, in the case of a shaft being renewed,
use the manufacturer's alignment markings.
Apply Loctite 242 to threads of all flange bolts. A B

Retaining straps C stretch with use, therefore these straps
must always be replaced with new ones.
Note: Propshafts should be installed with their main shaft S157510

sections fitted to the axle end, and their sliding sections
fitted to the transmission wheel drive unit.
Note: The propshaft must have both ends exactly on the

same plane as shown at X. The yokes must not be at right
angles as at Y or at an intermediate angle as at Z.
Torque Settings
Item
A
Nm
75 - 85
kgf m
7.7 - 8.7
lbf ft
55 - 63 C
B 118 12 87 A
X
S232350
Z A
S189610 S157500
9803/9240 Issue 2*
6-1 SD55/NT Axle 6-1
Drive Head - Dismantling
ITL00670
9803/9240 Issue 1
* Drive Head - Dismantling (cont’d) Drive Head - Assembly
! WARNING Pinion Depth Setting Procedure (see Note)

Place new pinion head bearing assembly on a flat surface
and position bearing cup 892/00174 over the bearing.
chocked. Do no rely solely on the machine hydraulics or
Measure gap A (e.g. 0.20 mm) and add this to the cup depth
stamped on the tool (e.g. 30.01 mm) to obtain the bearing
Disconnect the battery, to prevent the engine being depth.
GEN-1-1
1 Drain the oil from the drive head. Remove the propshaft.
2 To remove the drive head it is necessary to withdraw

both drive shafts from the axle (see Hub - Dismantling
and Assembly).
3 Remove the drive head carrier bolts 1. Mark the

installation position of drive head carrier 2 relative to the ITL00560
axle housing.
From the face of the pinion, obtain the etched deviation
4 Remove the drive head carrier from the axle housing. figure (e.g. + 2) which is in units of 0.01 mm. If positive, add
this to the bearing depth; if negative, subtract from the
5 Pull out the roll pins 3 and remove the castellated nuts bearing depth.
4. Remove the outer races of bearings 5 and 6 from the
drive head carrier bores. Obtain the deviation figure (e.g. - 1) stamped on the
differential housing bolt flange. If negative, add to bearing
*6 Remove bearings 5 and 6 together with inner bearing depth; if positive, subtract from bearing depth.
races.
Subtract the total of the above figures form the standard
7 Remove differential assembly 8 from carrier. valve of 31.19 mm. The result will be the thickness of shims
required behind the pinion head bearing cup.
8 Loosen the differential case half bolts 7 and pull the
case halves 8A and 8B apart. Remove the axle bevel Example (all dimensions in millimetres)
gears 9, the differential bevel gears 10, trunnion pin 11
and thrust washers 12 from the case halves.
Cup depth 30.01
9 Remove the thrust washers 13 from both case halves. Cap A +0.20
Bearing depth 30.21
10 Remove the bolts 14 and separate the crown wheel 15 Pinion deviation (+ 2) +0.02
from the case half 8A. Housing deviation (- 1) +0.01
Total 30.24
11 Remove pinion nut 16. Use Service Tool 892/00812 to
prevent drive yoke 18 from rotating. Standard value 31.19
Less Total above 30.24
12 Remove the drive yoke.
Shim Thickness 0.95
13 Drive pinion shaft 20 out of drive head carrier 2. Note: See page 5/6-5 for general guidance on crownwheel
and pinion adjustment.
14 Prise shaft seal 19 out of the bore.
15 Remove taper roller bearing 21 and tap out the outer

bearing race.
16 Tap out the out race of bearing 22 from the opposite

bearing housing and remove the drive pinion shim(s) 23.
17 Remove spacer 24 from drive pinion 20. Prise taper

roller bearing 22 to raise it sufficiently to insert bearing
pullers. Pull the bearing from the pinion shaft.
9803/9240 Issue 3*
Drive Head - Assembly (cont’d)
ITL00670
9803/9240 Issue 1

9 Drive bearing cones 5 and 6 onto differential case
Note 1 Both the crownwheel 15 and pinion 20 and the bevel
gears 9 and 10 are matched and should be renewed as sets spigots. Lightly oil the bearings then fit their bearing
if any of their components are damaged or excessively cups and castellated nuts 4 into drive head carrier 2.
worn. The two differential housing halves 8A and 8B are also Do not fit the roll pins 3 at this stage.
matched. Do not use unmatched halves.
10 Adjust castellated nuts 4 to give an increase in input
Make sure all bearings are lightly oiled before fitting and pinion rolling torque of between 1.36 - 2.5 Nm (12 - 22
setting. Make sure bearings are rotated whilst being set. lbf in) more than that recorded in Step 4.
1 Select shim 23 required for pinion depth setting and fit 11 Measure the backlash between crownwheel 15 and
behind new bearing cup 22. (See Pinion Depth Setting pinion 20, which should be 0.17 - 0.28 mm (0.006 -
Procedure, page 5/6-2). *
0.011 in). Adjust castellated nuts 4 by equal amounts
when altering backlash. When backlash and preload
2 Fit new pinion head bearing cone 22 onto pinion 20. are both correct, fit roll pins 3.
3 Fit a new collapsible spacer 24 onto pinion 20. Lightly 12 Check tooth marking as per page 5/6-5. If incorrect,
oil pinion head bearing 22. Lightly oil pinion tail bearing adjust.
21 and fit the bearing. Using a suitable drift tap the tail
bearing fully into position in the carrier. Locate the 13 Apply Loctite 275 to the mating faces of drive head
pinion in carrier 2. (Before inserting, ensure that the carrier 2 and the axle casing. Fit the drive head carrier
pinion matches crownwheel 15.) Insert a new oil seal 19 * to the axle casing, taking note of the mark made during
into housing. Pack grease between the seal lips. Fit dismantling. Fit securing bolts 1 and and torque tighten
drive yoke 18 using a new stake nut 16. see note below:
* Note: The preferred option is to fit a solid spacer 24. See
* Note: Torque Settings for bolt 1 is dependent on the type of
Soild Spacer Assembly. bolt used:
M10 56 Nm (42 lbf ft, 6 kgf m)
4 Tighten the stake nut 16 to collapse spacer 24 until end M10 Verbus Ripp 94 Nm ( 69 lbf ft, 9.6 kgf m)
float is almost zero, then check the seal drag torque is
between 0.40 - 0.75 Nm (3.54 - 6.64 lbf in). Continue to
tighten the stake nut to collapse spacer 24 and give a 14 Reassemble both driveshafts and hub assemblies (refer
rolling torque of 1.5 - 2.8 Nm (1.1 - 21 lbf in) (excluding to page 5/9-4).
seal drag). Rotate flange 18 in each direction to bed in
the bearings before measuring. Stake the nut when the Re-fill the hubs and differential with the correct grade of
pre-load is correct. oil (see Lubricants and Capacities, Section 3). Refit
the propshaft.
Note 2: If the specific rolling torque is exceeded, the
collapsible spacer will be distorted. Renew the spacer and
start again.
5 Assembly the trunnion pin 11, bevel gears 9 and 10 and

their thrust washers 12 and 13 into differential half case
8A (see Note 1 above).
*6 Position differential half case 8B onto half case 8A,

aligning the match-mark letters (see Note 1 above).
Apply Loctite 242 to the threads of bolts 7, then fit and
torque tighten, see Note. Check the gears for free
rotation.
* Note: Torque Settings for bolt 7 are dependent on the type

of bolt used:
M8 46 Nm (34 lbf in, 4.7 kgf m)
M10 56 Nm (41 lbf in, 5.7 kgf m)
M10 Flange head bolt 98 Nm (72 lbf in, 10 kgf m)
7 Fit crownwheel 15 using new Verbus Ripp bolts 14

tightened to 94 Nm (69 lbf ft, 9.59 kgf m).
8 Locate crownwheel assembly (without bearings) into

housing.
9803/9240 Issue 2*
Crownwheel and Pinion Adjustment
Meshing of the gears should be checked by marking three of

the pinion teeth with engineers marking compound and
rotating the pinion.
The marking will then be transferred to the crown wheel

teeth.
Correct tooth marking.
ITL00600
Pinion too deeply in mesh.
Decrease the shim thickness between the pinion inner

bearing cup and the axle casing. Move the crown wheel
towards the pinion to correct the backlash.
ITL00610
Pinion too far out of mesh.
Increase the shim thickness between the pinion inner

away from the pinion to correct the backlash.
ITL00620
9803/9240 Issue 1
Drive Head with Limited Slip Differential - Dismantling
9803/9240 Issue 2*
Drive Head with Limited Slip Differential -

Dismantling (cont’d) 10 Rotate side gears 15 to eject planet gears 13 and thrust
washers 14. Lift out side gears, pressure plates
*Note: Some axles may be fitted with a Two Piece Limited 19,counter plates 17, friction plates 18 and shims 16.
Slip Differential, see Two Piece Limited Slip Differential for
dismantling and assemby. 11 Check the condition and security of bushes 20 (see
Note below).
Note: The number of friction and counter plates shown in the
illustration is typical only. The actual number of plates is Note: Later type differential assemblies are not fitted with
specified by the manufacturer and must not be altered bushes 30; instead, the differential assembly is machined so
without approval. that it supports the driveshaft.
The numerical sequence shown on the illustration is intended

as a guide to dismantling.
For assembly the sequence should be reversed.
! WARNING

GEN-1-1
1 Remove the planet gear carrier from both hub

assemblies and withdraw both drive shafts. (Refer to
page 5/9-2 for details of hubs and driveshafts -
dismantling.)
2 Remove the propshaft.
3 Drain oil from differential casing and remove securing

bolts 1. Discard gasket 3. Lift drive head 2 from casing.
Note: Item 3 is not fitted on later axles, instead Loctite 275

sealant is used.
4 Drive out roll pins 4 and unscrew castellated nuts 5 and

5A. Remove bearing cups 6.
5 Identify the manufacturer’s marks on the drive head

casing 2 and the bearing caps 2A for subsequent
assembly.
*
Remove bolts 2B and remove the differential from the
drive head. Remove bearings 7.
6 Using Service Tool 892/00812, remove drive yoke 22

and drive out pinion 23 complete with spacer 24.
Remove oil seal 25 and pinion tail bearing 26. Drive
pinion head bearing cone 27 from the pinion.
7 Remove pinion head bearing cup 28 with its shims 29.
8 Unscrew Verbus Ripp bolts 9 using heavy duty socket

892/00819 and remove crownwheel 10.
9 Remove bolt 11 and drive out trunnion pin 12.
9803/9240 Issue 3*
Drive Head with Limited Slip Differential - Assembly
9803/9240 Issue 2*

Assembly (cont’d)
1 Fit side gears 15, with pressure plates 19, counter 8 Determine Pinion Depth Setting (see Note 1)
plates 17 and friction plates 18 onto differential case 8.
a Place new pinion head bearing assembly on a flat
Note: Do not fit the shims 16 at this point. surface and position bearing cup 892/00174 over
the bearing. Measure cap A (e.g. 0.20 mm) and add
Position planet gears 13 and thrust washers 14 until this to the cup depth stamped on the tool (e.g.
they are engaged with side gears and diametrically 30.01 mm) to obtain the bearing depth.
opposed. Rotate side gears until planet gears and
washers align with trunnion pin bore.
2 Drive in trunnion pin 12 until bolt 11 can be located.
3 Using a dial test indicator, with two screwdrivers or

suitable levers, gently apply pressure to side gear 15
away from the trunnion pins 12 as shown. Measure and
note the end-float of the side gear.
ITL00560
b From the face of the pinion, obtain the deviation

figure (e.g. +2) which is in units of 0.01 mm. If
positive, add this to the bearing depth; if negative,
subtract from the bearing depth.
c Obtain the deviation figure (e.g. -1) stamped on the

differential housing bolt flange. If negative, add to
bearing depth; if positive, subtract from bearing
depth.
d Subtract the total of the above figures from the

standard value of 31.19 mm. The result will be the
thickness of shims required behind the pinion head
bearing cup.
Example (all dimensions in millimetres)

S171590
Cup depth 30.01

Cap A +0.20
4 Turn the differential assembly over and repeat step 3 Bearing depth 30.21
for the second side gear.
Pinion deviation (+ 2) +0.02
5 Dismantle the differential assembly. Add shims 16 to Housing deviation (- 1) +0.01
give end float between 0.1 and 0.2 mm (0.004 and Total 30.24
0.008 in).
Standard value 31.19
*6 Repeat steps 2, 3 and 4. If the end float is correct. Less Total above 30.24
Remove bolt 11 apply Loctite 275 to threads of bolt Shim Thickness 0.95
then fit and tighten to 28 Nm (20 lbf ft). If the end float
is not correct, adjust the shims accordingly.
Note1: See page 5/6-5 for general guidance on crownwheel
7 Fit crownwheel 10 using new Verbus Ripp bolts 9
tightened to 94 Nm (70 lbf ft). and pinion adjustment.
Note 2: Both the crownwheel 10 and pinion 23, side gears

15 and planet gears 13 are matched and should be renewed
as pairs if any of their components are damaged or
excessively worn.
9 Select shims 29 required for pinion depth setting and fit

behind new bearing cup 28.
9803/9240 Issue 2*

Assembly (cont’d)
10 Press new pinion head bearing cone 27 onto pinion 23 17 Using a new gasket 3 (see Note), fit differential to axle
using press 892/00179 with adapters 992/07608 and casing with crownwheel towards long driveshaft. Fit
992/07609. securing bolts 1 and torque tighten see note below.
* Reassemble both driveshafts and hub assemblies and
11 Fit a new collapsible spacer 24 onto the pinion 23.
re-fill hubs and differential with the correct grade of oil
Lightly oil pinion head bearing 27 and locate the pinion
(see Lubricants and Capacities, Section 3). Refit the
in the housing. (Before inserting, ensure that the pinion
propshaft.
matches the crownwheel 10.) Lightly oil pinion tail
bearing 26 and fit the bearing. Using a suitable drift, tap
Note: On later axles, the gasket 3 is replaced by Loctite
the tail bearing fully into position in the housing. Insert a
275.
new oil seal 25 into housing. Pack grease between the
seal lips. Fit the drive flange 22 using a new stake nut
* Note: Torque Settings for bolt 1 is dependent on the type of
20 and washer 21.
bolt used:
M10 56 Nm (42 lbf ft, 6 kgf m)
* Note: The prefered option is to fit a solid spacer 24. See
M10 Verbus Ripp 94 Nm ( 69 lbf ft, 9.6 kgf m)
Solid Spacer Assembly.
* Note:On later machines, stake nut 20 and washer 21 are

combined. The separate nut and washer should be
discarded and replaced with the new combined nut and
washer.
12 Tighten the stake nut 20 to collapse spacer 24 until end

float is almost zero, then check the seal drag torque is
between 0.40 - 0.75 Nm (3.54 - 6.64 lbf in). Continue to
tighten the stake nut to collapse spacer 24 and give a
* rolling torque of 1.5 - 2.8 Nm (1.1 - 21 lbf in) (excluding
seal drag). Rotate flange 22 in each direction to bed in
the bearings before measuring. Stake the nut when the
pre-load is correct.
Note: If the specified rolling torque is exceeded, the

collapsible spacer will be distorted. Renew the spacer and
start again.
13 Fit bearing caps 2A using bolts 2B tightened to 165 Nm

(121 lbf ft). Make sure the correct manufacturer’s marks
are aligned.
Locate differential assembly (without bearings) into

drive head.
Note: Drive head casing 2 and bearing caps 2A are matched

and should be renewed as a complete assembly if damaged
or worn.
14 Drive bearing cones 7 onto spigots, lightly oil the

bearings then fit bearing cups 6 and castellated nuts 5.
Do not fit the roll pins 3 at this stage.
* 15 Adjust castellated nut 5 on crownwheel side until

backlash is 0.17 - 0.28 mm (0.006 - 0.010 in).
16 Adjust castellated nut 5A until there is no end float and

no pre-load, ensuring that bearings are bedded in by
rotating in each direction. Tighten nut 5A by a further 4
castellations to set pre-load, ensuring that correct
backlash is maintained. Fit roll pins 4.
9803/9240 Issue 2*

Assembly (cont’d)
Crown Wheel and Pinion - Adjustment
Meshing of the gears should be checked by marking three of

the pinion teeth with engineers marking compound and
rotating the pinion. the marking will then be transferred to
the crown wheel teeth. After every repair, check the
markings to verify settings.
Correct tooth marking.
ITL00600
Pinion too deeply in mesh.
Decrease the shim thickness between the pinion inner

bearing cap and the axle casing. Move the crownwheel
towards the pinion to correct the backlash.
ITL00610
Pinion too far out of mesh.
Increase the shim thickness between the pinion inner

away from the pinion to correct the backlash.
Note: Crownwheel teeth will fail prematurely if run in this

condition.
ITL00620
9803/9240 Issue 1
Section 5 Transmission Section 5
Drive Head Solid Spacer- Assembly
ITL00670
9803/9240 Issue 1*
Drivehead Soild Spacer - Assembly

(cont’d)
The outline procedure below refers to the fitting of a soild
spacer to the drivehead assembly. For dismantling and
assembly of the drivehead see the relevant DriveHead
Dismantling and Assembly sections.
Note: Special tools are required for the following procedure,

see Solid Spacer Setting Kit in Service Tools
1 Install pinion and bearings into the drive head casing.

Install largest available solid spacer 24 e.g (14.20 mm)
and fit pinion tail bearing 21 (lightly oiled). Do not fit the
oil seal 19 at this stage.
Note: It should be noted that the axle is assembled using a

solid spacer. However, in the absence of the special tools
required or the correct size solid spacer 24 it is acceptable
to fit a collapsible spacer, refer to applicable Axle Hub and
Driveshaft Assembly.
E
2 Fit special tool sleeve B and special pinion shaft C
adapter C. Tighten adapter C to approximately 50 Nm,
making sure the pinion is free to rotate and there is end
float, this will prevent any damage to the bearing. If the D B
pinion is not free to rotate or there is no end float at this
stage check the bearing is fitted correctly. Also check
the correct size spacer has been fitted.
3 Fit special bracket D to the drive-head housing using

two M10 x 30 nuts and bolts. Fit special tool support 348030
pillar E to bracket D so that the fork end engages in
adapter C. Ensure that fork E is centrally located on
adapter C. If necessary, re-align bracket D to suit.
4 Fit dial test indicator (DTI) F. Ensure that the DTI is G

mounted on the drive head and not on bracket D.
5 Set torque wrench G to 35 Nm (25.8 lbf ft) and measure

the end float while rotating the shaft. F
6 To select the right size spacer 24, subtract the end float
obtained at step 7 from the solid spacer size (14.20
mm). Also subtract 0.04 mm to allow for theoretical
bearing tolerance and pre load. The result is the size of
spacer to be fitted from the solid spacer setting kit. If
there is no spacer of this size, fit the next nearest size
spacer, refer to Service Tools - Axles.
Example
Temporary spacer size 14.20
Subtract end-float 0.25
348040
Total 13.95
Subtract tolerance & preload 0.04
Result 13.91
(No spacer available this size, use next nearest size
spacer i.e 13.900)
9803/9240 Issue 1*
7 - 10 SD55/NT Axle 7 - 10
Drivehead Soild Spacer - Assembly

(cont’d)
7 Remove sleeve B and temporary spacer. fit correct size

spacer from solid spacer setting kit, refer to Service
Tools - Axles. During removal take care to avoid
damaging the outer bearing.
8 Fit sleeve B. Tighten adapter C to no more than 50 Nm

to protect against bearing damage while spacer
selection is verified making sure the pinion is free to
rotate. Check there is no end float and pinion is free to
turn smoothly by hand. Remove adapter C and fit nut
16. Then check that rolling torque is less than 2.0 Nm. If
the rolling torque exceeds 2.0 Nm, check that the shaft
has been assembled correctly.
Note: If the pinion is not free to rotate check the correct size
spacer has been fitted.
9 If rolling torque measured at step 8 is too high, fit the

next larger size spacer. If rolling torque is too low, fit
the next smallest size spacer. If a correct spacer is not
available from the range, check that drive head is
assembled correctly.
10 Remove adapter C and sleeve B. Fit new oil seal 19,

grease between seal lips before fitting. Fit coupling
yoke 18 and NEW stake nut 16.
11 Progressively torque tighten stake nut 16, occasionally

rotating coupling yoke, up to 250 Nm. Providing the
correct size spacer has been selected the rolling torque
should be between 2.3 and 3.4 Nm including seal drag.
Note: The nut tightening torque can be increased to a

maximum of 300 Nm provided that the pinion rolling torque
does not exceed the maximum of 3.4 Nm.
12 Finally stake the nut 16 into the slot.
9803/9240 Issue 1*
7 - 11 Rear Axle 7 - 11
Two Piece Limited Slip Differential
6 7 8 14
9
1 10 13
12
10
9
8
7
6
3
11
S171530
S212790
9803/9240 Issue 1*
7 - 12 Rear Axle 7 - 12
Two Piece Limited Slip Differential
Dismantling Friction Plate Wear Limits
The numerical sequence shown on the illustration is intended Measure and note the thickness of the friction plate, the
as a guide to dismantling result must not be less than 1.25 mm (0.049 in).
The two differential halves are matched, before dismantling Check the condition of the friction material, which should be
mark the two halves for subsequent assembly. even over both surfaces.
Note the relative positions of the friction and counter plates If in doubt, discard the set (friction and counter plates).
before dismantling, they must be fitted in the same positions.
If worn, the friction and counter plates must be renewed as a

complete set.
Assembly
1 Assemble trunnion pins 12, side gears 11 with pressure
plates 10, counter plates 8, friction plates 9, planet
gears 13 and thrust washers 14 into the 'crownwheel
half of the differential assembly 5.
Note: Do not fit the shims 6 at this point.
2 Align the two halves of the differential assembly with the

marks made during dismantling. Assemble using bolts
3.
3 Using a dial test indicator (or feeler gauges), with two

screwdrivers or suitable levers, gently apply pressure to
side gear 11 away from the trunnion pins 12 as shown.
Measure and note the end-float of the side gear.
4 Turn the differential assembly over and repeat step 3 for

the second side gear.
5 Dismantle the differential assembly. Add shims 6 to give

end-float between 0.1 and 0.2mm (0.004 and 0.008in.).
Note: Shimming must be carried out whenever the differen-

tial is dismantled, however the end float 0.1 and 0.2 mm
(0.004 and 0.008 in.) can be exceeded on previously assem-
bled differential as this is only an initial setting figure which
allows for bedding in.
6 Repeat steps 2, 3, and 4. If the end float is correct, tight-

en bolts 3 to 56 Nm (41 lbf ft 5.7 kgf m).
7 Fit crownwheel 2 using new Verbus Ripp bolts 1, tighten

bolts to 94 Nm (69 lbf ft 9.6 kgf m).
9803/9240 Issue 1*
Renewing the Pinion Oil Seal
The pinion oil seal 4 may be renewed without removing the *4 Check the sealing surface on the yoke for wear or
axle from the machine. damage, renew the yoke if necessary.
! WARNING *5 Fit the yoke and temporarily fit the old stake nut 2.
Tighten the nut with a torque wrench, aligning the
scriber marks. Note the tightening torque required.
chocked. Do not rely solely on the machine hydraulics or *6 Remove and discard the old nut. Fit a new nut and
tighten to the torque determined at step 5.
6.1 Measure the rolling torque. The reading should be
0.5 to1Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m)
more than that recorded in Step 1 (see Note).
GEN-1-1
6.2 If necessary, progressively torque tighten the nut to

1 Remove the roadwheels and uncouple the axle
a maximum of 300 Nm (221 lbf ft) to achieve correct
propshaft. Measure the axle rolling torque and record
rolling torque.
the reading. Mark the relative positions of the pinion
shaft and nut with a scriber.
Note: If the rolling torque figure (new pinion seal fitted)
exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft;
2 Using Service Tool 892/00812, remove the drive yoke 1
0.1 kgf m) or more, or a minimum torque of 250 Nm (184 lbf
together with its stake nut 2 and washer 3.
ft) can not be achieved then the pinion assembly must be re-
built using a solid spacer, see the appropriate axle assembly
* Note:On later machines, stake nut 2 and washer 3 are
procedure.
combined. The separate nut and washer should be
discarded and replaced with the new combined nut and
6.3 Stake the nut using a square ended staking tool.
washer.
7 Refit the roadwheels and couple the propshaft.
3 Remove the seal 4 and fit a new one.Take care not to
damage the seal housing. Pack between the lips of the
new seal with grease before fitting.
9803/9240 Issue 2*
Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled)

Dismantling
*
9803/9240 Issue 5*
Axle Hub and Driveshaft - 2 Plate, Positive 8 Remove brake piston back-up bolt 13A and spring 13B
(2 or 3 off each). Carefully withdraw brake piston 13
Retraction Brakes (Dowelled) (cont’d) from its housing, if removal is necessary. A hydraulic
Dismantling (cont’d) hand pump can be used to force the piston out of the
housing, or if the brakes system is still connected use
! WARNING the brake pedal. Remove and discard seals 14 and 15.
Make the machine safe before getting beneath it. Park
the machine on level ground. Make sure the engine is 9 Remove brake plate carrier C and spacer D.
stopped, the parking brake engaged and the transmision 10 Remove Verbus Ripp bolts 18. These bolts are very
is in neutral. Disconnect the battery. chock both side of tight and care must be taken not to distort the bolt
all four wheels. heads. Use as short an extension bar as possible with a
5-3-2-1
six sided socket. Discard Verbus Ripp Bolts after
*1 Disconnect the track rod and steering rams, drain oil removal.
from the axle hub, remove bolts 1.
11 Using special tool (part number 892/00833) as jacking
Note: If the track rod is to be removed completely, identify screws, jack the annulus assembly 21, 22 and 23 off
R.H. and L.H. ends to ensure correct assembly. bearing carrier 19. Ensure that ring dowels 20 remain
either in the axle arm or the annulus carrier 21.
2 Using a soft-faced mallet, tap the planet gear carrier 2
to ‘crack’ the joint between the carrier and bearing Note: Fretting between the hub swivel and annulus carrier
carrier 19, then lever the planet gear carrier off the mating faces might be evident; this condition is normal, do
bearing carrier. Remove and discard ‘O’ ring 3. not attempt to repair. If the hub swivel and annulus carrier
are to be re-used, the carrier must be assembled in the
3 Remove a planet gear 4 only if it is defective. Note that same angular position it was removed; match mark the hub
a planet gear can only be renewed as an assembly, swivel and carrier before removing the carrier.
* which comprises the gears, the bearing 5 and two ‘L’
shaped circlips 6. To remove a planet gear, first remove 12 Remove internal circlip 22 to separate annulus ring 23
external circlip 7, then pull off the planet gear. Remove from annulus carrier 21.
circlip A, sun gear B.
* Note: A Hub Service Kit (892/01092) is available for the
4 The stubshaft thrust pad 8 is drilled and tapped M6 for removal and replacement of the hub bearings. See Axle Hub
removal purposes. Bearing, Removal and Replacement.
5 Remove circlip 9 and brake pressure plate 10. Remove 13 Pull off bearing carrier 19 together with outer wheel
shims X. bearing cone and cup 24. Withdraw the inner bearing
6 There are three counterplates 11 and two friction plates cup from the inboard side of the carrier.
12. If the brake pack is to be re-used, note the 14 Pull off inner wheel bearing 25.
positions of the plates before removing them.
15 Remove combination seal 26.
7 Wear limit of friction plates 12 is to the depth of the
crosshatching. Check all plates for flatness and * 16 Remove dirt shield 38 (if fitted).
damage. (Wear and polishing of the counterplates 11 is
normal.) Renew the brake pack complete if excessively Note: The top and bottom trunnions are very similar (bottom
worn or damaged. Do not renew individual plates. trunnion not illustrated), the only difference being that shims
* (if fitted) 29 are fitted to the top trunnion only.
Note: Excessive wear of the brake and counter plates can
indicate sticking brakes or possible residual pressure in the 17 Mark position of top and bottom trunnions 28, remove
braking system. See Residual Brake System Pressure, bolts 27 and remove trunnions. Retain shims 29 (if
Section 6. fitted) with top trunnion. Withdraw the hub carrier 30.
*
Note: Later type axles have ‘paper’ friction plates, these can Note: Trunnions may be removed easily and without
be readily identified because they do not have radial slots. damage to the shims (if fitted) by pumping grease through
DO NOT mix the two differential types of friction plates. the grease nipple.
18 Remove the top and bottom trunnion seals 31 and
bearings 32.
19 Withdraw driveshaft 33 from the axle casing. Prise out
driveshaft outer oil seal 34. Remove bearing 35 using
tool 892/00225.
20 Prise out driveshaft inner oil seal 36.
22 Remove circlip 37.
22 Remove bearing 38 using tool 892/00225.

A276990
23 If there has been a component failure remove all traces
of debris and clean the magnetic drain plug.
9803/9240 Issue 5*
Axle Hub and Driveshaft - 2 Plate, Positive Retraction Brakes (Dowelled) (cont’d)
9803/9240 Issue 5*
Axle Hub and Driveshaft - 2 Plate, Positive 11 Refit top trunnion. Apply Loctite 242 to the top trunnion
Retraction Brakes (Dowelled) (cont’d) bolt threads, fit and tighten to 98 Nm (72 lbf ft; 10 kgf m).
Assembly (cont’d) Check spring balance reading which should be 4.5 kgf
Note: The top and bottom trunnions are very similar (bottom (10 lbf) more than the reading recorded at Step 9.
trunnion not illustrated), earlier axles may have shims 29
fitted to the top trunnion. 12 Connect the track rod and steering cylinder to the axle
steer knuckles.
1 Tap the driveshaft inner bearing 38 into position in the
axle casing. 13 Lightly oil inner wheel bearing 25 and its cup, then fit
them into bearing carrier 19.
2 Fit circlip 37.
* Note: A Hub Service Kit (892/01092) is available for the
3 Fit new oil seal 36. Pack grease between the lips of the
removal and replacement of the hub bearings and seals. See
seal.
Hub Bearing, Removal and Replacement.
4 Tap the driveshaft outer bearing 35 into position in the
hub swivel driveshaft bore.
seal.
X
6 Fit driveshaft 33, taking care to locate the inner end into
the splines of the differential gears.
7 Press new top and bottom trunnion oil seal 31 into

position followed by bearings 32. Grease bearing and
oil seal before fitting axle.
8 Locate hub swivel 30 and fit bottom trunnion 28. Apply

Loctite 242 to threads of bottom trunnion bolts 27 and
then torque tighten bolts to 98 Nm (72 lbf ft; 10 kgf m). A272 0
14 Fit a new combination seal 26 into the bearing carrier.

* Note: On later models without shims 29, torque tighten the
Using service tool 892/00891, drive the seal squarely
top bolts 27. Turn the swivel by hand, to ensure smooth
into the carrier until flush as at X. Do not lubricate
operation. If swivel is stiff to turn, dismantle and check that
before fitting.
seal 31 is seated correctly. Go to step 12.
15 Install the cup of outer wheel bearing 24 into the
bearing carrier 19. Grease the bore of the seal and the
surface of the stub.
* 16 Check condition and refit the dirt shield 38 (if fitted). Fit
bearing carrier 19 onto hub swivel 30.
Note: The bearing carrier must be fully supported during the

fitting operation; do not allow any weight to rest on the
bearings otherwise the inner bearing will be displaced an d
damage the seal.
S160251 Note: After assembling the bearing carrier to the swivel hub,
make sure that there is sufficient clearance between the hub
9 Attach a spring balance to track rod swivel as shown
and seal.
and note the reading. Tighten the top trunnion bolts 27
to eliminate end float but without bearing pre-load, i.e. 17 Lightly oil the bearing race of outer wheel bearing 24.
no increase in spring balance reading. Fit the bearing onto the axle stub. Rotate carrier 19
*
(and therefore the bearings) during fitting.
10 Measure gap at top trunnion and subtract 1 mm (0.040
in) to give shim thickness (bearing pre-load). For 18 Assemble the annulus ring 23 to annulus carrier 21.
example: Secure with circlip 22. Make sure the two blanking
Gap = 1.55 mm (0.061 in) plugs Z are fitted to the annulus carrier. Apply Loctite
less = 1.00 mm (0.040 in) 242 to threads.
Shim = 0.55 mm (0.021 in)
Note 2: Inspect the inside of the annulus carrier and piston
for marks. Any signs of scoring on a seal contact surface can
Note 1 : If the gap measures 1 mm, then no shim is
cause leaks.
required.
Note 2: If, after fitting shims the bearing pre-load is Note 3: Make sure blanking screws Y are fitted. Apply Loctite
unattainable, fit new bearings. 242 to threads.
9803/9240 Issue 5*
Axle Hub and Driveshaft - 2 Plate, Positive

Retraction Brakes (Dowelled) (cont’d)
Assembly(cont’d)
* 19 Fit the annulus assembly in the same angular position * 23 Carefully press the piston 13 all the way into its
as removal (see Note, Dismantling, Step 11) using new housing. Fit brake piston back-off springs 13B and
Verbus Ripp bolts 18. Do not fully tighten bolts but bolts 13A (2 off each). Torque tighten to 5 Nm (0.5 kgf
allow the bearing carrier to rock slightly. m, 3.5 lbf ft).
20 Temporarily refit the planet gear carrier 2, DO NOT fit 24 Assemble the friction plates 12 and counterplates 11
the sun gear. onto the stubshaft and annulus ring 23. If the original
brake pack is being re-used, return the plates to their
Check the seal drag rolling force: original positions (see Dismantling, Step 6). Soak new
friction plates in gear oil before assembly.
i Use a spring balance and cord wrapped around the
planet gear carrier flange as shown. Pull the spring 25 Add shim(s) X (if fitted)and assemble the brake pressure
balance so that the hub rotates, do several times to plate 10 with its chamfer towards the brake pack. Make
let the seal bed in and record the reading. sure the shim(s) fit between items 10 and 11. The
shim(s) should give a gap of 1.5 mm to 1.8 mm (0.060
to 0.070 in). This can be measured by putting a dial test
indicator (DTI) on the end face of item 10 and
pressurising the brakes, or alternatively, use feeler
gauges inbetween items 10 and 9. When the correct
gap has been achieved fit circlip 9.
* Note: Shims X are only fitted to early axles.
Note 4: Where axles are fitted to machines utilising the main

hydraulic circuit to operate the brakes:
i Bleed the brake system. Gently apply the brakes and

release the pressure with the engine running. Check the
piston activates and retracts correctly and does not
stick in the applied position before fitting the hub carrier.
ii Remove the planet gear carrier and tighten M14 ii If the brake piston has not yet retracted, the brake seal
Verbus Ripp bolts 18 to 320 Nm (236 lbf ft, 33 kgf or piston assembly may have been assembled
m). incorrectly. Alternatively, there may be residual hydraulic
brake pressure holding the piston - Release the brake
iii Repeat steps 20, 20i and record the reading. bleed nipple with the engine running and check if the
piston retracts when the pressure is released.
iv To get the rolling force, subtract seal drag rolling Investigate the cause if the piston remains in the applied
force (see Step 20i) from reading obtained at this position (see Residual Brake System Pressure,
step, the result should be 13.6 to 150 N, (3 to 34 lbf; Section 6).
1.4 to 15.3 kgf).
26 Fit sun gear B and circlip A.
If the resulting figure is outside these limits check;
the seal 26 is fitted correctly; and/or renew bearings 27 Press the stubshaft thrust pad 8 (chamfered side
24 and 25. lowermost) into the recess in the planet gear carrier 2.
Note: A high rolling force reading may indicate that the oil 28 Fit new planet gears 4 in place of any that were
seal was damaged during fitting. removed (see Step, 3 in Dismantling). Secure with
circlip 7.
v Remove the planet gear carrier 2.
Note: Large radius at end of bearing bore fits onto pin first.
21 Fit spacer D and brake plate carrier.
22 Lubricate new seals 14 and 15 with hydraulic oil and fit

them into their grooves in the brake piston 13 and
annulus carrier 21. Make sure they seat squarely in their
grooves.
9803/9240 Issue 5*
* Axle Hub and Driveshaft - 2 Plate, Positive

Retraction Brakes (Dowelled) (cont’d)
* Assembly(cont’d)
* 29 Fit new ‘O’ ring 3.
Fit the planet gear carrier 2 onto the bearing carrier 19,
turning it slightly to engage the gear teeth and aligning
the two tapped holes W in the planet gear carrier with
their mating holes in the bearing carrier. (The tapped
holes are diametrically opposite one another.) Ensure
the planet gear carrier butts fully against the bearing
carrier.
* Note: Do not strike the centre of the planet gear carrier 2

when fitting, as this may dislodge the stubshaft thrust pad 8.
* 30 Fit bolts 1 and torque tighten to 52 Nm (38.3 lbf ft, 5.3
kgf m).
* 31 Fill the axle hub with oil (see Lubricants and
Capacities, Section 3).
9803/9240 Issue 2*
9-7 SD55/NT Axle 9- 7

Retraction Brakes (Splined)
* Dismantling
9803/9240 Issue 3*

Retraction Brakes (Splined) (cont’d) Note: Excessive wear of the brake and counter plates can
indicate sticking brakes or possible residual pressure in the
Dismantling (cont’d) braking system. See Residual Brake System Pressure,
Section 6.
! WARNING
Make the machine safe before getting beneath it. Park 11 Remove Verbus Ripp bolts 14 and remove retaining
the machine on level ground. Make sure the engine is plate 15.
stopped, the parking brake engaged and the
12 Remove brake seal 16 then mark the relationship
transmission is in neutral. Disconnect the battery. Chock
between the annulus carrier 17, annulus ring 18 and
both side of all four wheels.
5-3-2-1 hub swivel 30, remove the annulus carrier 17 with
annulus ring 18 from the hub swivel 30.
1 Disconnect the track rod and steering rams. Remove
plug 1 and drain the oil from the hub. 13 Remove circlip 19 to separate annulus ring from
annulus carrier. Remove brake seal 20 from hub swivel.
Note: If the track rod is to be removed completely, identify
R.H. and L.H. ends to ensure correct assembly. 14 Remove brake piston back off bolt 21A and spring 21B
(3 off each). Carefully withdraw brake piston 21 from its
2 Remove bolts 2. housing. A hydraulic hand pump can be used to force
the piston out of the housing.
3 Lever off the planet gear carrier 3 at the levering points.
Remove and discard ‘O’ ring 4. 15 Remove and discard seals 22 and 23. Inspect the
housing bore for damage and scoring. Nicks or cuts in
4 Remove planet gears 5 only if defective. Note that the
the seals may be responsible for loss of brake fluid.
gears can only be removed as assemblies, which
comprise the gear, the bearing and two ‘L’ shaped
circlips. To remove a planet gear, first remove the * Note: A Hub Service Kit (892/01092) is available for the
removal and replacement of the hub bearings. See Axle Hub
external circlip 6.
Bearing, Removal and Replacement.
5 Pull off the planet gear 5.
16 Pull off bearing carrier 24 together with the outer
6 The driveshaft thrust pad 7 is drilled and tapped M6 for bearing 25.
removal purposes.
17 Pull off inner bearing 26.
7 Remove circlip 8 to allow the sun gear 9 to be slid off
* 18 Remove seal 27 and remove dirt shield 38.
the driveshaft.
Note: The top and bottom trunnions are very similar (bottom
8 Remove circlip 10 to allow the brake pack assembly to trunnion not illustrated).
be slid off the driveshaft.
19 Mark the position of the top and bottom trunnions 33,
9 Remove brake pressure plate 11, counter plates 12 and remove bolts 32 and remove trunnions. Withdraw the
friction plates 13. hub carrier 30.
Note: If the brake pack is to be re-used, note the positions 20 Remove the top and bottom trunnion seals 34 and
of the plates before removing. bearings 35.
21 Withdraw driveshaft 31 from the axle casing. Prise out
10 Examine friction plates, wear limit is to the depth of the
driveshaft inner oil seal 29. Remove bearing 28 using
crosshatching. Check all plates for flatness and
tool 892/00225.
damage. Some scoring of the counterplates is normal.
Renew the brake pack complete if worn or damaged.
Do not renew individual plates. 32
33
30
34
35
A276990
S303741
9803/9240 Issue 3*

Retraction Brakes (Splined) (cont’d)
* Assembly
*
A 06 0
9803/9240 Issue 3*
9 - 10 SD55/NT Axle 9 - 10

Assembly (cont’d)
1 Tap driveshaft inner bearing 29 into position in the hub 11 Fit new brake seal 20 to hub swivel.
swivel driveshaft bore.
12 Lubricate and fit new seal 22 onto the piston 21 and
2 Fit new oil seal 28. Pack grease between lips of seal. seal 23 into the annulus carrier 17. Make sure they seat
3 Fit driveshaft 31, taking care to locate inner end into the squarely in their grooves.
splines of the differential gears.
13 Carefully press the piston 15 all the way into the
4 Press new top and bottom trunnion oil seal 34 into annulus carrier housing 17. Fit brake back-off springs
position followed by bearing 35. Grease bearing and oil 21B and bolts 21A (2 off each). Torque tighten to 5 Nm
seal before fitting to axle. (0.5 kgf m, 3.5 lbf ft).
5 Locate hub swivel 30 and fit bottom trunnion. Apply 14 Align relationship marks made on dismantling.
Loctite 242 to threads of trunnion bolts 32 and then Assemble the annulus ring 18 to the annulus carrier 17.
torque tighten bolts. Secure with the circlip 19. Make sure the two blanking
plugs X are fitted to the annulus carrier. Apply Loctite
6 Fit top trunnion 33, apply Loctite 242 to the threads of 242 to threads.
trunnion bolts 32 and then torque tighten bolts.
Note: Inspect the inside of the annulus carrier and piston for
7 Lightly oil the inner wheel bearing race 26. Assemble marks. Any signs of scoring on a seal contact surface can
the bearing cup and bearing race into the bearing cause leaks.
carrier 24.
Note: Make sure blanking screws Y are fitted. Apply Loctite
* Note:A Hub Service Kit (892/01092) is available for the 242 to threads.
Hub Bearing, Removal and Replacement. 15 Fit annulus assembly onto splined hub, check that
relationship mark aligns. Push the annulus assembly
onto the splined hub until the splines of the annulus
assembly are flush with the end of the splined hub. Fit
brake seal 16 onto hub swivel.
X 16 Fit retaining plate 15, make sure the brake galleries

align. Secure using new Verbus Ripp bolts 14 and
tighten until the annulusw assembly just rocks.
17 Measure seal drag rolling force, see page 5/9-5, Step

20i to v. Note: Torque tighten the new Verbus Ripp
bolts 14 to 166 Nm (72 lbf ft, 10 kgf m)
18 Assemble the friction plates 13 and counterplates 12

onto the carrier. If the original brake pack is being used,
return the plates to their original positions as noted
A272 0 during dismantling. Soak new friction plates in gear oil
before assembly.
8 Fit combination seal 27 into the bearing carrier.
Using service tool 892/00891, drive the seal squarely 19 Fit brake pressure plate 11 and circlip 10.
into the carrier until flush as at X. Do not lubricate
20 Press the driveshaft thrust pad 7 (chamfered side
before fitting.
lowermost) into the recess in the planet carrier 3.
*9 Inspect and fit dirt shield 38. 21 Fit new planet gears 5 in place of any that were
removed during dismantling. Secure with circlip 6.
* 10 Lightly oil the outer wheel bearing race 25 and inner
bore of seal 27. Assemble the bearing cup and bearing 22 Slide sun gear 9 onto the driveshaft and secure with
race into the bearing carrier 24. Fit the bearing carrier circlip 8. Fit a new ‘O’ ring 4 in place of the one
24 onto the axle stub. discarded during dismantling.
23 Fit planet carrier 3 onto bearing carrier 24 ensuring that
Note: The bearing carrier must be fully supported during the
the two tapped holes are in line with those on the
fitting operation; do not allow any weight to rest on the
bearing carrier. Fit and tighten bolts 2 after applying
bearings, otherwise the inner bearing will be displaced and
Loctite 242 to the threads.
damage the seal.
24 Reconnect the steer arms.
9803/9240 Issue 2*
9 - 11 SD55/NT Axle 9 - 11

Assembly (cont’d)
Torque Settings
1 70 - 100 7.1 - 13.8 51.5 - 73.75
2 56 5.71 41.3
* 14 166 10 72
21A 5 0.5 3.5
32 98 10 72
32
33
30
34
35
S303741
9803/9240 Issue 2*
10 - 1 SD55/NT Axle 10 - 1
Axle Hub and Driveshaft -

SD40 Non Braked Hub
Dismantling
9803/9240 Issue 1*
10 - 2 SD55/NT Axle 10 - 2

SD40 Non Braked Hub (cont’d)
Dismantling (cont’d)
15 Mark position of top and bottom trunnions 27, remove
1 Drain oil from the axle hub. bolts 26 and remove trunnions.
2 Remove bolts 24. Note: Trunnions may be removed easily by pumping grease
through the grease nipple.
3 Using a soft-faced mallet, tap the planet gear carrier 18
to ‘crack’ the joint between the carrier and bearing
16 Remove the top and bottom trunnion seals 29 and
carrier 8, then lever the planet gear carrier off the
bearings 30 only if they are to be replaced. Removing.
bearing carrier. Remove and discard ‘O’ ring 23.
will damage the seals.
4 Remove planet gears 25 only if it is defective. Note that
17 Withdraw drive shaft 21 from the axle casing.
a planet gear can only be renewed as an assembly,
which comprises the gears, the bearing 5 and two ‘L’
18 Prise out drive shaft outer oil seal 2.
shaped circlips 19. To remove a planet gear, first
remove the external circlip 4, then pull off the planet
gear.
20 Prise out driveshaft inner seal 31.
5 The driveshaft thrust pad 17 is drilled and tapped M6
for removal purposes.
21 Remove circlip 32.
6 Remove external circlip 22 and spacer 35.
7 Remove Verbus Ripp bolts 16. These bolts are very
23 If there has been a component failure, remove all traces
tight and care must be taken not to distort the bolt
of debris and clean the magnetic drain plug.
heads. Use as short an extension bar as possible with a
six sided socket. Discard the Verbus Ripp bolts after
removal.
8 Pull the annulus assembly 12, 13 and 14 off the bearing

carrier 8.
Note: Ensure annulus ring position is marked for

reassembly.
If the hub swivel and annulus carrier are to be renewed they

must be renewed as pairs and not individually.
9 Remove internal circlip 14 to separate the annulus ring

12 from the annulus carrier 13.
10 Pull off the bearing carrier 8 together with the outer

wheel bearing cone and cup 11. Withdraw the inner
bearing cup from the inboard side of the carrier.
Note: A Hub Service Kit (892/01092) is available for the

removal and replacement of the hub bearings. See Axle Hub
11 Pull off the inner wheel bearing 6.
12 Remove the dirt shield 34.
13 Remove and discard combination seal 9.
14 Disconnect the track rod and steering cylinder from the

axle steer knuckles.
trunnion not illustrated).
9803/9240 Issue 1*
10 - 3 SD55/NT Axle 10 - 3

Assembly
9803/9240 Issue 1*
10 - 4 SD55/NT Axle 10 - 4

Assembly (cont’d)
trunnion not illustrated),
1 Tap the drive shaft inner bearing 33 into position in the

hub swivel driveshaft bore, secure with circlip 32. X
2 Fit new oil seal 31. Pack grease between lips of seal.
3 Fit driveshaft 21, taking care to locate inner end into

splines of differential gears.
4 Tap driveshaft outer bearing 1 into position in the hub

swivel.
seal.
A272 0
6 Press new top and bottom trunnion oil seals 29 into
position followed by bearings 30. Grease bearing and
oil seal before fitting axle.
7 Locate hub swivel 3 and fit bottom trunnion 27. Apply 14 Fit the bearing carrier 8 onto the hub swivel 3.
Loctite 242 to threads of bottom trunnion bolts 26 and
then torque tighten bolts. Torque tighten the top bolts 15 Lightly oil the bearing race of outer wheel bearing 11.
26. Turn the swivel by hand, to ensure smooth Fit the bearing onto the axle arm. Rotate the carrier 8
operation. If swivel is stiff to turn, dismantle and check (and therefore the bearings) during fitting.
that seal 29 is seated correctly. Go to step 11.
16 Assemble the annulus ring 12 to the annulus carrier 13.
Secure with circlip 14.
Note: Item 26
M10 bolts torque to 56 Nm (42 lbf ft; 6 kgf m). Note: After assembling the bearing carrier to the swivel hub,
M12 bolts torque to 98 Nm (72 lbf ft; 10 kgf m). make sure that there is sufficient clearance between the hub
and seal.
8 Connect the track rod and steering cylinder to the axle
steer knuckles. 17 Fit annulus assembly in the same angular position as
removal (see Note on page 5/10-2) using new Verbus
Note: A Hub Service Kit (892/01092) is available for the Ripp bolts 16. Do not fully tighten bolts but allow the
removal and replacement of the hub bearings and seals. See bearing carrier to rock slightly.
Note: Steps 18 describe measurement of rolling force. To
9 Inspect and fit dirt shield 34. measure rolling torque (simplified process), a special tool is
available. Refer to Service Tools.
10 Lightly oil the inner wheel bearing 6 and its cup 7, then
fit them into the bearing carrier 8.
cont..
11 Fit a new combination seal 9 into the bearing carrier.
Do not lubricate before fitting. Using service tool
(892/00891) and spacer, drive the seal squarely into
carrier 19, until flush, as shown at X.
13 Install the cup of outer wheel bearing 10 into the

bearing carrier 8. Lubricate the bore of the seal and the
surface of the stub.
9803/9240 Issue 1*
10 - 5 SD55/NT Axle 10 - 5

Assembly (cont’d) 21 Fit spacer 35 and secure driveshaft with circlip 22. Fit a
new ‘O’ ring 23.
18 Check the seal drag rolling force: Fit planet gear carrier 27 onto bearing carrier 8, turning
it slightly to engage the gear teeth and aligning the two
i Use a spring balance and cord wrapped around the tapped holes A in the bearing carrier. (The tapped holes
planet carrier flange as shown. Pull the spring are diametrically opposite one another.) Ensure the
balance so that the hub rotates, do several times to planet gear carrier butts fully against the bearing
let the seal bed in and record the reading. carrier.
ii Remove the planet gear carrier and tighten new Note: Do not strike the centre of the planet gear carrier 18
Verbus Ripp bolts 16 to 166 Nm (122 lbf ft, 17 kgf when fitting, as this may dislodge the driveshaft thrust pad
m). 17.
iii Repeat steps 19, 19i and record the reading. 22 Fit bolts 24 and torque tighten to 56 Nm (41.3 lbf ft,
5.71 kgf m).
iv To get the rolling force, subtract seal drag rolling
23 Fill the axle hub with oil (see Lubricants and
Capacities, Section 3).
force (see Step 19i) from reading obtained at this

step, the result should be 2 to 22 Nm, (3 to 34 lbf;
1.4 to 15.3 kgf).
If the resulting figure is outside these limits check

the seal 9 is fitted correctly and/or renew bearings 6
and 11.
Note: A high rolling force reading may indicate that the oil
seal was damaged during fitting.
19 Press the driveshaft thrust pad 17 (chamfered side

lowermost) into the recess in the planet gear carrier 18.
20 Fit new planet gears 25 in place of any that were

removed (see Dismantling, Step 4 ). Secure with circlip
5.
Note: The large radius at end of bearing bore fits onto the
pin first.
9803/9240 Issue 1*
11 - 1 SD55/NT Axle 11 - 1

SD70 Non Braked Hub
16
Dismantling
4 7
6
5 15
6 13
2
9
12 14
10 11 34
8 35
20
43
3
17
19
27
28
18
24
29
25
31
23
32
30
21
22
26
710050
9803/9240 Issue 1*
11 - 2 SD55/NT Axle 11 - 2

1 Disconnect the steering track rod. Drain oil from the

hub.
Note: The illustration shows a typical axle.
2 Remove bolts 1.
3 Lever the planet gear carrier 2 off the bearing carrier.

Clean off all traces of sealant from the mating faces or
remove ‘O’ ring as applicable.
4 Remove planet gears 4 only if defective. Note that gears

can only be removed as assemblies, which comprise
the gear 4, the bearing 5 and two 'L' shaped circlips 6.
To remove a planet gear, first remove the external
circlip 7.
5 Pull off the planet gear 4.
6 The driveshaft thrust pad 8 is drilled and tapped M6 for

removal purposes.
8
7 Remove circlip 9 to allow the sun gear to be slid off the
drive shaft 34.
8 To remove the ‘Verbus Ripp’ bolts 12, it is necessary to

remove the spacer 11. Revolve the spacer with a
suitable drift to align the holes in the spacer with the 255920
space between the bolts.
9 Using two dowels and two heel bars, remove the spacer
11 using the method shown.
10 Remove the 'Verbus Ripp' bolts 12 using a special tool

(part number 892/00333). These bolts are very tight and
care must be taken not to distort the bolt heads. Use as
short an extension bar as possible.
11 Using 2 high grade M12 bolts as jacking screws,

remove the annulus carrier.
Note: Fretting between the hub swivel and annulus carrier

mating faces might be evident; this condition is normal, do
not attempt to repair. If the hub swivel and annulus carrier
are to be re-used, the carrier must be assembled in the same
angular position it was removed; match mark the hub swivel
and carrier before removing the carrier.
12 Remove circlip 15 to separate the annulus ring from the

annulus carrier.
255930
9803/9240 Issue 1*
11 - 3 SD55/NT Axle 11 - 3


removal and replacement of the hub bearings. See Hub
13 Pull off the bearing carrier 17 together with the outer X

bearing cone 18 and its bearing cups.
Note: To prevent damaging the axle case inner seal, do not

lever against the half shaft. Place a tube over the half shaft
and lever against the tube, as shown at X.
14 Pull off the inner bearing 19 - see Note at step 13.

A258390
15 Remove and discard the seal 20.
Note: The inner bearing and oil seal may withdraw with the
bearing carrier.
16 Remove and discard the combination seal. When

assembling the axle, a new combination seal must be
used.
17 Remove the dirt shield 35.
18 Mark position of top and bottom trunnions 27, 3 and

remove. Withdraw the hub carrier.
Note 1: Trunnions may be removed easily by pumping

grease through the grease nipple.
Note 2 : Earlier axles are fitted with shims 29. Remove shims
and retain for assembly.
19 Use an adaptor with slide hammer tool 892/00224 and

remove driveshaft seal 21 and needle roller bearing 22
from the hub carrier 30.
20 Use a puller to remove the trunnion seal 31 and bearing

32.
21 Withdraw drive shaft 34.
22 Prise out drive shaft inner oil seal 23.
23 Remove circlip 24
9803/9240 Issue 1*
11 - 4 SD55/NT Axle 11 - 4

SD70 Non Braked Hub
16
Assembly
4 7
6
5 15
6 13
2
9
12 14
10 11 34
8 35
20
43
3
17
19
27
28
18
24
29
25
31
23
32
30
21
22
26
710050
9803/9240 Issue 1*
11 - 5 SD55/NT Axle 11 - 5

Assembly (cont’d)
1 Tap drive shaft inner bearing 25 into position and
secure with circlip 24.
2 Fit new oil seal 23. Pack grease between lips of seal.
3 Fit drive shaft 34, taking care to locate inner end into
splines of differential gears.
4 Fit new trunnion oil seal 31 into position followed and

press bearing 32 into position. Grease bearing and oil
seal before fitting to axle.
5 Fit driveshaft needle roller bearing 22 to the hub carrier

30. Pack the cavity between the oil seal lips with grease
and then fit the seal 21.
6 Locate hub carrier and fit bottom trunnion 3. Apply

Loctite 242 to the bottom trunnion bolt threads 26, fit
and tighten to 98Nm (72 lbf ft). Fit top trunnion 27 and
leave top trunnion bolts 26 finger tight.
Note: On later models without shims 29, torque tighten the

top bolts 27. Turn the swivel by hand, to ensure smooth
operation. If swivel is stiff to turn, dismantle and check that
seal 31 is seated correctly and check bearings 32. Go to
step 11.
7 Attach a spring balance to track rod swivel as shown

and note the reading. Tighten the top trunnion bolts 26
to eliminate end float but no bearing pre-load, ie no
increase in spring balance reading.
Note: Earlier axles are fitted with shims 29. 07 60
Measure gap at top trunnion and subtract 1 mm (0.040

in) to give shim thickness (bearing pre-load). S248850
For example:
Gap = 1.55 mm (0.061 in)
less 1.00 mm (0.040 in)
Shim = 0.55 mm (0.021 in)
Note 1: If the gap measures 1 mm, then no shim is required.
8 Refit top trunnion. Apply Apply Loctite 242 to the top

trunnion bolt threads 27, fit and tighten to 98 Nm (72 lbf
ft). Check spring balance reading which should be 4.5
kgf (10 lbf) more than the reading recorded at step 7.
Note 2: If after fitting shims, the bearing pre-load is

unattainable, fit new bearings.
9 Lightly oil the inner wheel bearing 19. Assemble the

inner and outer bearing cups, and the inner bearing
cone into the bearing carrier 17.

9803/9240 Issue 1*
11 - 6 SD55/NT Axle 11 - 6

SD70 Non Braked Hub (cont’d) Y X 35
Assembly (cont’d)
10 Inspect and fit dirt shield 35.
11 Fit a new combination oil seal 20. Do not lubricate B A

before fitting. Use seal dolly L (892/00891) to fit the 20 20
seal. Be sure to use the correct side of the dolly (the
dolly is stamped A and B) as follows: L A
Axles with steel dirt shield 35, use side A as shown at X.
Axles with no dirt shield 35, use side B as shown at Y. 17
Fit the seal over the dolly and then use a soft faced
hammer to drive the seal squarely into the carrier until
B
the dolly flange is up against the carrier.
12 Fit the bearing carrier 17 onto the axle arm. Lightly oil
A 02 0
the outer wheel bearing race 18 and inner bore of seal
20. Fit the bearing onto the axle stub. Rotate the
bearing during fitting.
13 Assemble the annulus ring 16 to the annulus carrier 13.

Secure with the circlip 15.
14 Fit annulus assembly in the same angular position as

removal (see Note, Dismantling, step 11) using new
'Verbus Ripp' bolts 12. Do not fully tighten bolts but
allow the bearing carrier to rock slightly. Measure seal
drag rolling force - see step 14.
Note: Steps 13 to 16 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool
is required. Refer to Service Tools.
15 To measure seal drag rolling force:
- Refit the planet gear carrier - DO NOT FIT THE SUN

GEAR 10.
- Use a spring balance and cord wrapped around the

planet carrier flange as shown.
- Pull the spring balance so that the hub rotates, do

several times to let the seal bed in and record the
reading.
- Remove planet gear carrier 2.
16 Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33

kgf m) and then measure rolling force - see step 16.
17 To measure rolling force:
- Refit the planet gear carrier - DO NOT FIT THE SUN

GEAR. Use a spring balance and cord wrapped
around the planet gear carrier flange as shown. Pull
the spring balance so that the hub rotates and
record the reading.
- To get the rolling force, subtract seal drag rolling

force (see step 14) from reading obtained at this S248540
step, the result should be 64 to 117 N (14 to 26 lbf).
9803/9240 Issue 1*
Section F Transmission Section F
11 - 7 Front Axle - SD55, SD70 11 - 7

Assembly (cont’d)
17 cont’d
- If the resulting figure is outside these limits check: the
seal is fitted correctly; and/or renew bearings if
necessary; and /or new fitted components.
- Remove planet gear carrier 2.
18 Press the drive shaft thrust pad 8 (chamfered side

lowermost) into the recess in the planet carrier.
8
19 Fit new planet gears in place of any that were removed.
(See step 4 in 'Dismantling'). Secure with circlip 6.
Note: Make sure that the SMALL radius on the gear bearing
internal diameter is facing uppermost, that is at the circlip
end of the planet pin.
255920
20 Fit spacer 11 and slide the sun gear 10 onto the

driveshaft 34 and secure with circlip 9. Fit a new ‘O’
ring 3 in position X.
Note: Some machines may have sealant instead of an‘O’

ring - where appropriate fit a new ‘O’ ring.
X
Note: The sun gear must be fitted with the 1.5 mm (0.060 in)
x 45° chamfer inboard.
21 Fit the planet carrier 2 onto the bearing carrier, ensuring

that the two tapped holes are in line with those on the
bearing carrier 17. Fit and torque tighten bolts 1 to
56Nm (41Ibf ft; 5.7kgf m) after applying Loctite 242 to
the threads.
Note: Rotate planet gear carrier slightly to align the gears.

Do not strike the centre of the planet gear carrier when fitting
as this may dislodge the driveshaft thrust pad 8 fitted at
step 17.
22 Fill the axle hub with oil (see Lubricants and

Capacities, Section 3)
S258230
9803/9240 Issue 1*
14 - 1 SD55/NT Axle 14 - 1
Axle Hub Bearing
Removal
9803/9240 Issue 1*
14 - 2 SD55/NT Axle 14 - 2
Axle Hub Bearing
Removal (cont’d)
1 Remove the planet gear carrier 2, annulus ring 16 and Y

the annulus carrier 14. See Axle Hub and Driveshaft
Dismantling.
Note: The Bearing Puller from the Wheel Hub Service Kit
882/01092 (see Service Tools) is required throughout steps
C
13 to 17.
2 Assemble the puller B, screwing the legs A onto, two A

diametrically opposite wheel studs and placing reaction
tube C over the driveshaft.
D
Note: Reaction Tube C, MUST be used, otherwise damage B
to the driveshaft and drive shaft bearings will occur.
A439380
Note: On five wheel stud axles, the modified wheels studs

from the Wheel Hub Service Kit must be used. Bolt to two
diametrically opposite holes provided on the bearing carrier
12. X
3 Screw in D slowly until the bearing carrier together with
the outer bearing cone and its cup are released from
the axle. If the wheel hub starts to turn use a suitable
bar Y to prevent further rotation.
Note: If D becomes to hard to turn, tap the back of the hub

with a plastic hammer to help release the bearing.
4 Remove and discard the outer part of combination seal

19 by cutting the outer seal with a sharp chisel X.
Carefully force the inner seal fully on to the stub axle,
taking CARE not to damage the seal seat on the stub
axle. If a dirt shield 22 is fitted, it may need to be
removed (clearance for the inner bearing plate E is
required).
5 Assemble the puller B, with the inner bearing plate E

clamped around the inner bearing 18, (If a dirt shield 22
is fitted, it may need to be removed) attach the puller
rods F and reaction tube C over the driveshaft 26.
C
Note: Reaction tube C, MUST be used, otherwise damage
to the driveshaft and driveshaft bearings will occur.
E
6 Slowly screw in D until the bearing 18 is released.
Remove and discard the inner section of seal 19. F
D
B A439390
9803/9240 Issue 1*
14 - 3 SD55/NT Axle 14 - 3
Axle Hub Bearing
Replacement
9803/9240 Issue 1*
14 - 4 SD55/NT Axle 14 - 4
23
Axle Hub Bearing
Replacement (cont’d)
1 Fit the dirt shield 22 to the stub 23 (if fitted).

H
Note: The bearing press from the wheel hub service Kit
882/1092 (see Service Tools) is required throughout steps 2
to 11.
2 Attach the bearing centre puller H to the centre of the

hub 23 using the existing ‘Verbus Ripp’ bolts 11.
Note: When refiting the annulus carrier 14, NEW ‘Verbus

Ripp’ bolts must be used. Y X 22
3 Install outer bearing race from bearing 17 into bearing
carrier 12.
4 Install the inner bearing 18 into the bearing carrier 12.

Fit a new combination oil seal 19. Do not lubricate
B A
before fitting. Use seal dolly L (892/00891) to fit the
19 19
seal. Be sure to use the correct side of the dolly (the
dolly is stamped A and B) as follows:
Axles with steel dirt shield 22, use side A as shown at X. L A
Axles with no dirt shield 22, use side B as shown at Y.
Fit the seal over the dolly and then use a soft faced 12
hammer to drive the seal squarely into the carrier until
the dolly flange is up against the carrier. B
5 Lightly oil the inner wheel bearing 18 and seal 19 inner
diameter. Position the bearing carrier (complete with A 02 0
inner bearing) onto the stub over the centre puller H.
6 Slide the bearing fitting tube K over the centre bearing

puller H (the wide opening towards the bearing). Make
sure that the bearing and carrier are square to the shaft.
7 Attach the puller handle J to the bearing centre puller

H, making sure that the thrust bearing is fitted between
two thrust washers at L. Using the puller handle, screw
in the bearing fitting tube K until the inner bearing 18 is
pressed correctly into postion.
8 Remove the puller handle J and bearing fitting tube K.
9 Install the outer bearing 17 in the bearing carrier 12.
10 Assemble the puller handle J and bearing fitting tube K

onto the centre puller H. L
11 Using the puller handle J, screw in the bearing fitting
tube K until the outer bearing 17 is pressed correctly
into postion so as to remove most of the free play. Do
not over tighten as this may cause damage to the
bearing.
K
12 See Axle Hub and Driveshaft Assembly.
9803/9240 Issue 1*
Section 6 Brakes Section 6
i i
Contents Page No.
Service Brakes
Technical Data 1-1
Bleeding Procedure 2-1
Dismantling and Assembly 2-1
* Residual Brake System Pressure 2-1
* Brake Seal or Component Leakage 3-1
9803/9240 Issue 2*
Service Brake - 2 Plate, Positive Retraction (Power Braked Machines)

Type Oil-immersed multi-plate disc
Actuation Hydraulic
Location Outboard - Axle Hub
* Friction Plates 2 per brake (i.e. 4 per axle)

Outside diameter 220 mm (8.66 in)
Inside diameter 180 mm (7.09 in)
Nominal facing area/plate 12616 mm2 (19.5 in2)
9803/9240 Issue 2*
2-1 Service Brakes 2-1
Bleeding Procedure * Residual Brake System Pressure

Bleed as follows: If residual pressure is greater than the pressure required to
overcome the brake retraction springs in the axle, brake
a Attach tube to bleed screw A, ensuring that free end of piston retraction will not occur resulting in excessive heat
tube is immersed in hydraulic fluid contained in a and wear of brake components.
suitable jar.
If the residual pressure in the braking system is above 0.35
b Open bleed screw A and apply one rapid stroke of the bar (5 lbf/in2) in the hot condition, the system should be
brake pedal followed by three rapid short strokes from checked to identify the cause of the problem.
the pedal half way position. After the third short stroke
allow the pedal to return quickly to its stop. Note: Pressure cannot build up in the hydraulic tank until the
oil is hot, or if the pressure is vented by removing the tank
c Continue bleeding normally until all air is expelled. cap/breather.
Close bleed screw A with the pedal fully depressed.
Checking for Residual Pressure
d Repeat the procedure for the other side.
The following checks should be done with the engine running
and the oil at working temperature.
Dismantling and Assembly 1 Apply and release the brakes. Check the brakes release
immediately.
The brakes are located in the wheel hubs. Instructions for
dismantling and assembly are detailed under Axles - Axle 2 If the brakes do not release immediately, place a
Hub and Driveshaft, Section 5. container under the axle hub to catch any spilt oil.
Unscrew the bleed nipple on the axle hub to release any
residual pressure.
Note: The same effort should be needed to rotate the

hub with the bleed nipple either open or closed. If the
problem affects one hub only, strip and inspect the
affected hub.
3 If the brakes release immediately, residual pressure

should be suspected.
4 If the brakes do not release immediately, tighten the

bleed nipple and check the following:
A
(a) Foot brake valve adjustment and linkage
(b) Operation of the hydraulic tank breather
(c) Clear plastic return lines from foot valve are not
restricted
(d) Hydraulic tank not over-filled
S144521
9803/9240 Issue 2*
Brake Seal or Component Leakage

3.3 If the pressure falls off rapidly, or if no pressure
The following procedure explains how to check if a brake reading can be obtained, a seal is severely
seal or component is severely damaged/perished, or if the damaged and needs replacing, or a leak path
seal has a small cut or nick. The test must only be done exists.
when the axle is COLD.
3.4 Remove planet hub and identify the source of the
! WARNING leakage before proceeding any further.
Before working on the brake system make sure the
machine is on level ground and chock all four wheels. Test For a Low Pressure Leak
BRAKE 1-4
4 Check for small cuts or nicks in the piston seal:

! WARNING
Do not drive the machine with any part of its brake 4.1 Install an adapter fitted with a piece of clear tube
system disconnected. When the following test has been to the brake piston port B, as shown at Y.
completed reconnect all brake pipes and bleed the brake
system using the recommended procedure. Note: The tube must be kept vertical during the
BRAKE 2-1
test, use tape to attach the tube to the side of the
machine.
Test For a High Pressure Leak
4.2 Fill the tube until approximately three quarters full
1 Remove and cap brake piston feed pipe A.
with Mobil DTE 11M Hydraulic Fluid
2 Fill the brake piston housing with Mobil DTE 11M
4.3 Using a suitable pen, mark the level line of the
Hydraulic Fluid.
brake fluid on the tube, as shown at C.
3 Check for severe piston seal damage:
4.4 After approximately 1/2 hour, check if the level has
dropped below the original marked line, if it has
3.1 Install a hand pump fitted with a 0 - 40 bar (0 - 600
then check the brake component for slight nicks,
lbf/in2) pressure gauge to port B, as shown at X.
cuts, leak paths or generally for wear.
Note: The hand pump MUST be filled with Mobil
5 Repeat steps 1 to 4 for the opposite brake piston seal.
DTE 11M Hydraulic Fluid. DO NOT exceed 69 bar
2
(1000 lbf/in ).
6 Reconnect all brake pipes and bleed the brake system
3.2 Use the hand pump to generate a pressure in the as recommended on page 6/2-1.
brake piston housing.
X Y
C
B
B
A A
159831
9803/9230 Issue 1
Brake Seal or Component Leakage

(cont’d)
The following areas identify where leakage can commonly
The most common reason for internal piston seal leakage is occur.
a build-up of axle contamination from excessive brake wear
caused by extended service periods. This allows metal Low Pressure:
particles to build-up on the sealing surfaces causing scoring
and allowing low pressure leaks. A Swivel to annulus carrier sealing o-rings and sealing
surfaces.
There are two types of internal leakage that can occur within
the axle and hub: B Brake piston seals.
(a) Low Pressure Leaks - Seal damage, or scoring to seal C Annulus carrier to swivel sealing o-ring surfaces.
component surfaces.
D Piston and annulus carrier sealing surfaces (porosity,
(b) High Pressure Leaks - Mechanical leakage through a scores, nicks & scratches etc.).
porous casing, or blanking screw threads.
High Pressure:
Note: The low pressure leak test should be performed first.
Low pressure leaks are difficult to find using a high pressure E Blanking screws (x2) - missing, loose or no thread
test - seals and other components can distort and form a sealant used.
seal under pressure.
F Porosity through casing from internal galleries.
G Blanking screws (x2) - missing, loose or no thread

sealant used.
H Annulus carrier to piston seals sealing surfaces.
G
B
H C
D
316010
A
9803/9230 Issue 1

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JCB Drivetrain System 9803-9240 Service Manual

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General Information 1

Care & Safety 2

Tel: (01978) 661140 NOTE

Date Page Issue Changes

Sept 2003 Cover 7 Issue number raised.

1/3 - 1 3 Service Tool list Updated

Date Page Issue Changes

1/Cont i 3 Axle Build Specification was Limited Slip Differential.

5/9-1 3 Blanking plugs Y and Z added to illustration.

5/9-3 4 Blanking plugs Y and Z added to illustration.

5/9-4 4 Notes added to items 16 and 18. Item 18 changed.

5/9-6 2 Information moved from 9-5.

5/9-9 2 Information moved from 9-8.

5/9-10 1 New page.

5/9-11 1 New page.

6/3-1 1 New page.

6/3-2 1 New page.

Date Page Issue Changes

2/4-2 2 Warnings GEN-1-12 and GEN-1-13 added.

Date Page Issue Changes

1/1-1 3 Axle Build Identification heading was Limited Slip Differential.

Date Page Issue Changes

5/i 3 Items added for splined hub - Dismantling and Assembly.

5/1-1 3 General Description added. Brake type added.

5/9-1 3 Sub-heading changed.

5/9-3 3 Sub-heading changed.

5/9-4 3 Sub-heading changed.

5/9-5 3 Sub-heading changed. Item 20 was 17. Note to item 22 added.

5/9-6 1 New page.

5/9-7 1 New page.

5/9-8 1 New page.

5/9-9 1 New page.

Date Page Issue Changes

Intro 2 Item 6 Brakes added.

1/i 2 Limited Slip Differential added to contents.

1/1-1 2 Limited Slip Differential information added.

1/2-1 2 Grade 12.9 bolt list added.

1/3-1 2 Part numbers revised.

1/4-3 2 Service Tools added.

1/5-1 2 Part numbers revised.

3/i 2 Lubricants - Health and Safety added to contents.

3/1-1 2 Oil and grease specification revised.

3/1-2 1 New page - Lubricants - Health and Safety information added.

3/2-1 2 Service schedules revised.

3/3-1 2 Annotations corrected.

4/1-1 2 Valve pressures removed.

4/2-1 2 Note revised.

4/3-2 2 Grease and Sealant specification revised.

4/5-1 2 Item 3 corrected.

5/i 2 Contents titles revised and corrected.

5/1-1 2 Mounting and input items revised.

5/2-1 2 Illustration revised.

5/5-1 2 Grease specification revised.

5/6-2 2 Item 2 revised.

5/7-2 2 Note regarding friction plates added.

5/9-1 2 Illustration revised.

5/9-2 2 Items 2, 8, 10 and 14 revised. Items 20 to 23 added.

5/9-3 2 Illustration revised.

5/9-4 2 Item numbers revised.

5/9-5 2 Item numbers revised.

6/1-1 2 Friction plates revised from 3 to 2.

1 = General Information - includes torque settings and service tools.

Contents Page No.

Unit Identification 1-1

Steer Axle Movement/Shimming - Check G G G G