ZF - Axle Ap-17: Differential Carrier Type: Lkst-2 and LKZ - 7

Order-No.
: 5871 209 002 E
ZF – AXLE AP- 17
DIFFERENTIAL CARRIER
TYPE: LKST-2 AND LKZ - 7
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau Edition: 2001/01
REPAIR MANUAL
ZF - AXLE AP-17
DIFFERENTIAL CARRIER
TYPE: LKST-2 AND LKZ-7
INSTRUCTIONS CONCERNING THE REPAIR MANUAL
The described repair instructions are based on the design level of the ZF-Unit at the time of
preparation of this document.
Technical development of the product as well as extensions concerning the design possibilities may
require differing steps, which can be carried out by qualified specialists without greater difficulties
with the help of the Perspective Illustrations in the corresponding Spare Parts Lists.
For servicing and maintenance work on the brake system the specifications of the respective brake
manufacturer as well as of the vehicle manufacturer have to be observed.
Reference is also made to the attached original instructions of the component manufacturer,
ZF Part number 5871 209 102.
The present Manual is losing its legal obligation with the publication of a new successional Edition.
The ZF Passau GmbH is in this connection not responsible for the positive knowledge at the User of
the Manual!
ATTENTION:
For the installation as well as for commissioning of the unit, the Instructions and Specifications of the
Vehicle Manufacturer have to be observed!
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction même par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous reserve de modifications techniques!
2.Auflage / 2.Edition
Off-Road Transmissions
Repair Manual and Axle Systems
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PREFACE
This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair
and Maintenance operations on ZF-Units.
Treated is a ZF-Serial product according to the design stage of the date of Edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and
theoretical training is constantly completed to the actual situation in our Training School.
The Service Stations, established by the Zahnradfabrik Friedrichshafen all over the world, offer you:
1. Constantly trained personnel
2. Prescribed installations, e.g. Special Tools
3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability.
Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual
contractual conditions, by the ZF-Warranty.
Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-
expenditures eventually arising from it, are excluded from this contractual responsibility.
This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH
Service Department
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GENERAL
The Service Manual covers all works required for dismantling and the pertaining installation.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an exper-
like manner. The transmission should only be disassembled for renewing damaged parts. Covers and
housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and
nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction
bearings, bearing races, and similar, use suitable pulling devices.
Dismantling and mounting works must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re-installation of the parts, clean the contact surfaces of housings and
covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone. Clean
housings and locking covers with a suitable detergent, in particular corners and angles. Damaged parts or
parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as antifriction
bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign bodies
remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of the risk of functional failures in the control unit, the use of liquid sealing agents is not permitted.
By no means, Molykote is permitted to be used.
Lined plates must not be washed. They must be cleaned with a leather cloth.
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
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Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
the dismantled transmission. Dismantling and installing as well as the disassembly and assembly of a main
group are always summarized in one chapter.
Special tools required for performing the respective repair works are listed under „Special tools“.
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc.
CAUTION Is used, if a deviating and improper working procedure can damage

the product.
Is used, if lacking care can lead to personal injury or danger to

DANGER life.
___________________________________________________
REFE- Prior to starting the checks and repair works, thoroughly study the present instructions.
RENCE
CAUTION: Illustrations, drawings and parts do not always represent the original; the working procedure
is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description.
REFE- After the repair works and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again.
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

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

CONVERSION TABLE
TABLEAU DE CONVERSION
25,40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2,205 lb ( pounds )
9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)
1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5,560 lb / in ( pound per inch )
1 bar ( 1,02 kp/cm2 ) = 14,233 psi (pound force per squar inch lbf/in2 )
=
0,070 bar ( 0,071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4,456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )
=
3,785 Liter 1 Gallon ( US )
=
1609,344 m 1 Mile ( Landmeile )
0° C ( Celsius ) = + 32° F ( Fahrenheit )

=
0 ° C ( Celsius ) 273,15 Kelvin
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TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE

GLEASON GEAR-TOOTH SYSTEM
EXEMPLES POUR LA DENTURE GLEASON
Ideales Tragbild d.h. die Ritzeldistanz stimmt
Ideal tooth-contact pattern i.e. pinion distance is correct
L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte
Bild / Figure 1/3/5 Bild / Figure 1
Schubflanke (Konkav)
Coast side (concave)
Côté poussé (concave)
Bild / Figure 2/4/6 Bild / Figure 2
Zugflanke (Konvex)
Drive side (convex)
Côté entraîné (convexe)
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Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden
Pinion distance must be increased Pinion distance must be decreased
La distance du pignon doit être augmentée La distance du pignon doit être diminuée
(+) (-)
Bild / Figure 3 Bild / Figure 5
Bild / Figure 4 Bild / Figure 6
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TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARDS 148
Friction value: µ tot.= 0,12 for screws and nuts without after-treatment, as well as phophatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO-Standard thread DIN 13, Page 13

Dimension 8.8 10.9 12.9
M4 2,8 4,1 4,8
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine thread DIN 13, Page 13

Dimension 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 120 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300
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MAINTENANCE INSTRUCTIONS
1. OIL QUALITY: To ZF List of Lubricants TE-ML 05

ATTENTION: The respective updated list can be requested from all
ZF Service Centers and in the Internet under
www.zf-group.de.
2. OIL CHANGE: Drain-, filler- and level plugs must be cleaned carefully before opening!
Place the vehicle in a horizontal plane!
Drain oil only immediately after a longer running time!
Safety regulations of the vehicle manufacturer have to be observed!
2.1 Oil drain - Output (Figure 1)
Loosen screw plug and cap screw (arrows) and

drain oil.
Fig. 1
2.2 Oil drain – Axle insert LKST-2 (Figure 2):
Loosen screw plugs (arrows) and drain oil from the

axle casing as well as from the layshaft.
Fig. 2
2.3 Oil drain – Axle insert LKZ-7 (Figure 3):
Loosen screw plugs (arrows) and drain oil from axle

casing, layshaft and interaxle differential.
Fig. 3
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2.3 Oil filling - Output (Figure 4):
Install cap screw (arrow).

Note:
Wet thread of the cap screw with sealing
compound (Loctite, Type No. 574)!
Tightening torque (cap screw) ..... MA = 280 Nm
Fill up oil according to oil level marking.

Then provide the screw plug with a new O-ring
and install it.
Tightening torque ................ MA = 150 Nm

Fig. 4
2.4 Oil filling – Axle insert LKST-2 (Figure 5 and 6):
Provide both screw plugs (arrows 1 and 2) with new

O-rings and install them.
Tightening torque (M24x1,5) .............. MA = 70 Nm 3

Tightening torque (M42x1,5) .............. MA = 150 Nm
Fill up a constant oil quantity of 1,5 liters into the filler hole of
1
the layshaft housing (arrow 3). 2
Provide screw plug with a new O-ring and install it.
Tightening torque (M42x1,5) ....... MA = 150 Nm Fig. 5
Then fill up the oil into the filler hole of the axle casing
(arrow 4) to the overflow.
4
Check the oil level after some minutes and if required
fill up the oil until the specified level is reached and
remains constant.
Tightening torque (M42x1,5) ............ MA = 150 Nm
Fig. 6
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2.5 Oil filling – Axle insert LKZ-7 (Figure 6 a. 7)

Provide screw plugs 1, 2 and 3 with new O-rings and install 4
them.
Tightening torque (M24x1,5) ................. MA = 70 Nm
Tightening torque (M42x1,5) ................. MA = 150 Nm 5
Fill up a constant oil quantity of 1,5 liters into the filler hole of 1
the diff.-housing (arrow 4) as well as the layshaft housing
(arrow 5). 2 3
Provide screw plugs with new O-rings and install them.
Tightening torque (M42x1,5) ................. MA = 150 Nm Fig. 7
Then fill up oil into the filler hole of the axle casing (arrow 6).
Check the oil level after some minutes and if required fill up the
oil until the specified level is reached and remains constant.
6
Tightening torque (M42x1,5) ............... MA = 150 Nm
Fig. 8
3. OIL CHANGE INTERVALS:
1. Oil change after 500 operating hours.

Further oil changes every 1000 operating hours, however, at least once a year!
4. OIL LEVEL CHECK:
Oil level check once a month, but especially before starting a vehicle as well as for new or repaired axles.
.
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LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
ZF - PLANETARY – Axle AP - 17
1. Disassembly and Reassembly of the Output
4464 014 165/167/168/169
Disassembly Reassembly Designation and application of the special tools (S) Part No.
Chap./Figure Chap./Fig.
1/1 Assembly truck assy with tilting device 5870 350 000
Holding fixture 1 Set = 2 pcs. 5870 350 077
Clamping braces 1 Set = 2 pcs. 5870 350 075
Universal use.
To install the complete axle onto the assembly truck.
1/4 Adjusting screws 1 Set = 2 pcs. 5870 204 023

Universal use.
Facilitates the disassembly of the planet carrier
4474 308 070 and the hub.
1/4 1 / 50 Lifting tackle 600 N 5870 281 058

Universal use.
Facilitates the dis- and reassembly of the planet carrier.
1 /5 1 / 45 Set of external pliers A1-A2-A3-A4 5870 900 015

Universal use.
To snap out and to snap in externally clamped retaining
rings.
1/6 Two-armed puller 260 mm opening 5870 970 003

Universal use.
To remove the planet gear from the planet carrier.
1 / 10 1 / 36 Slotted nut wrench # 5870 401 141

1 / 40 To loosen and to tighten the slotted nut M120x1,5 0637
512 037 on the hub carrier.
To be used with:
Centering bracket # 5870 912 012
1 / 13 1 / 31 Lifting bracket # 1000 N 5870 281 043

Universal use.
To remove and to install the hub. Fastening to the wheel
bolt.
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4464 014 165/167/168/169
1 / 14 Crowbar set 2 pcs. required 5870 345 071

Universal use.
To separate components, disassembly of sealing rings,
bearings, etc.
1 / 18 Plastic hammer ∅ 60 mm 5870 280 004

Universal use.
To remove the brake disc from the hub.
1 / 19 Adjusting screws 1 Set = 2 pcs. 5870 204 026

Universal use.
Assembly aid for mounting of the brake and hub carrier
to the axle casing.
1 / 24 Driver 5870 050 008

To install the bearing outer rings 0750 117 437 or
0750 117 334 into the hub bore.
To be used with:
Handle 5870 260 004
1 / 25 Wheel bolt puller 5870 610 010

Combined with:
Insert M22x1,5 5870 610 002
To insert the wheel bolts 4474 306 180 into the hub bore.
1 / 27 Driver # 5870 051 050

1 / 28 To install the shaft seal Part 1 = 0734 319 631 = 170 x 200
1 / 29 x 13,5 / 20 = into the hub bore.
1 / 30 Pressure ring #
To press on the race Part 2 = 0734 319 631 onto the hub
carrier . 5870 506 132
To be used in combination with:
Handle 5870 260 004 .
1 / 35 Adjusting nut #
1 / 38 For determination of the exact thickness of the shim 5870 200 115
on the hub carrier.
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4464 014 165/167/168/169
1 / 36 Spring balance # 200 N 5870 230 007

Universal use.
For determination of the rolling resistance in the hub
bearing
1 / 46 Straightedge # 5870 200 022

1 / 47 Universal use.
For various measuring procedures.
Digital-Depth gauge # 5870 200 072
Gauge blocks # 100mm 1 Set = 2 pcs. 5870 200 067
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2. Disassembly and Reassembly of

ZF – Axle insert ,,LKST-2” 4460 028 032 / 034
Universal use.
2/3 2 / 94 Lifting chain 3-rope 5870 281 047

Universal use.
For various lifting work.
2/3 Back-off screws 1 Set = 2 pcs. 5870 204 010

Universal use.
Facilitates the removal and installation of the axle insert.
2/4 2 / 40 Assembly truck assy with tilting device 5870 350 000
2 / 11 Clamping ring 5870 350 103
To install the axle insert LKST-2 onto the assembly truck.
2/6 Hot-air blower 230V 5870 221 500

2 / 12 Hot-air blower 115V 5870 221 501
To heat the housing and transmission parts.
2/7 2 / 84 Gripping tongs 5870 281 013

Universal use.
Facilitates removal and installation of the differential assy.
2/8 Rapid grip M 95x2 5873 012 017

To pull off the tapered roller bearing inner ring
0750 117 414 = HM516 449 from the differential
cage.
Rapid grip
To pull off the tapered roller bearing inner ring 5873 013 012
0750 117 255 = JH716 649 from the differential cage.
To be used in connection with: 5873 003 011
Reducer M125x3/M95x2 5873 002 001
Basic set M 95 x 2
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2 / 10 2 / 67 Lifting chain 5870 281 047

Eye bolt assortment 5870 204 002
Universal use.
2 / 12 2 / 64 Fixture # 5870 240 025

Universal use.
To lock the input flange for loosening and tightening
the pinion belt connection.
Slotted nut wrench # 5870 401 045
To loosen the slotted nut M 52 x1,5 = 0737 502 187 .
2 / 14 Set of external pliers A1-A2-A3-A4 5870 900 015

Universal use.
To snap out and to snap in externally clamping retaining
rings.
2 / 15 2 / 41 Extractor 5870 000 065

2 / 23 2 / 49 Universal use.
2 / 26 2 / 53 To press the drive shaft or the input pinion out of the
axle drive housing. To preload the shafts in the axle
drive housing.
2 / 20 2 / 44 Magnetic block 1 Set = 3 pcs. 5870 450 003

Universal use.
To lock the pinion shaft when loosening and tightening the
slotted nut.

2 / 64 To loosen and to tighten the slotted nut 0737 502 146 on
the pinion shaft.
2 / 24 Gripping insert M 95x2 5873 002 034

To remove the bearing inner ring 31 316 = 0750 117 435
from the pinion shaft.
Basic set M 95 x2 5873 002 001
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2 / 32 Straightedge # 5870 200 022

2 / 35 Gauge blocks # 1 Set = 2 pcs. 5870 200 066
Digital-Depth gauge # 200 mm 5870 200 072
Universal use.
To measure the axle drive housing.
2 / 33 Shim # Ø 130 mm 5870 500 030

Shim # Ø 133,3 mm 5870 500 046
Measuring shaft # Ø 30 mm 5870 500 001
2 / 46 Torque spanner # 1 – 12Nm 5870 203 031

Universal use.
To check the rolling resistance in the pinion bearing.
2 / 61 Driver # EBM 5 + 1 mm 5870 048 236

To install the shaft seal 0634 319 303 into the cover.
2 / 79 Digital-Depth gauge # 200 mm 5870 200 072

2 / 80 Universal use. For various measuring procedures.
2 / 89 Magnetic stand # 5870 200 055

Digital indicator # 5870 200 057
Universal use.
To check the backlash crown gear/bevel gear.
2 / 90 Micrometer # 5870 340 510
To check the bracket width of the axle insert.
Plastic hammer ∅ 60 mm 5870 280 004

Universal use.
To separate, join and relieve housing- and
transmission parts.
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ZF – Axle insert ,,LKZ -7” 4460 028 033
Universal use.
3/3 3 / 94 Counter support 5870 300 020

Universal use.
In connection with:
Extractor 5870 000 091
To separate the flange shaft 4460 328 085 from the
axle casing.
3/4 3 / 147 Set of pliers A11-A21-A31-A41 5870 900 016

Universal use.
To snap out and to snap in externally clamping retaining
rings.
3/7 Back-off screws 1 Set = 2 pcs. 5870 204 010

Universal use.
Facilitates the removal of the axle insert from the axle
casing. 5870 281 047
Lifting chain 3- rope
Universal use.
3/8 3/8 Assembly truck assy with tilting device 5870 350 000
3 / 16 Clamping ring 5870 350 103
To install the complete axle insert LKZ-7 onto the
assembly truck.
3 / 10 Pry bar set 1 Set = 2 pcs. 5870 345 036

To loosen and tighten the adjusting nut in the axle insert.
To separate flanges, shafts and housing parts.
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3 / 11 3 / 95 Hot-air blower 230V 5870 221 500

3 / 17 3 / 148 Hot-air blower 115V 5870 221 501
3 / 39 To heat housing and transmission parts.
3 / 12 3 / 132 Gripping tongs 5870 281 013

Universal use.
Facilitates removal and installation of the differential assy.
3 / 13 Rapid grip M 95x2 5873 012 017

To pull off the tapered roller bearing inner ring 0750
117 414 = HM516 449 from the differential cage.
Rapid grip
To pull off the tapered roller bearing inner ring 0750
117 255 = JH716 649 from the differential cage. 5873 013 012
To be used in connection with:
Reducer M125x3/M95x2 5873 003 011
Basic set M 95 x 2 5873 002 001
3 / 15 3 / 68 Lifting chain 5870 281 047

3 / 19 3 / 115 Eye bolt assortment 5870 204 002
3 / 18 3 / 63 Fixture # 5870 240 025

Universal use.
To lock the input flange when the pinion bolting is
loosened or tightened.
To loosen the slotted nut M 52 x1,5 = 0737 502 187.
3 / 23 Two-armed puller opening 120 5870 970 002

Universal use.
To pull off the divided bearing inner ring
0635 340 069
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3 / 30 3 / 74 Locking device # 5870 240 040

To position and to fix the hollow shaft 4460 328 084
when the slotted nut is loosened and tightened.

To loosen and to tighten the slotted nut 0737 512 026 on
the hollow shaft 4460 328 084.
3 / 33 3 / 59 Extractor 5870 000 065

3 / 44 To press the hollow shaft 4460 328 084 and the bevel gear
shaft respectively out of the axle drive housing – bearing.
To preload shafts in the axle drive housing.
To press the bearing bush with spur gear out of the
axle drive housing.
For axial fixing of the bevel pinion when the single
parts are assembled.
3 / 40 3 / 62 Magnetic block 1 Set = 3 pcs. 5870 450 003

Universal use.
To lock the pinion shaft when the slotted nut 0737 502 146
is loosened and tightened.

To loosen and to tighten the slotted nut 0737 502 146 onto
the bevel pinion.
3 / 42 Gripping insert M 95x2 5873 002 034

To pull off the bearing inner ring 31 316 = 0750 117 435
from the pinion shaft.
To be used in connection with: 5873 002 001
Basic set M 95 x2
3 / 50 Straightedge # 5870 200 022

3 / 52 Gauge blocks # 1 Set = 2 pcs. 5870 200 066
3 / 53 Digital-Depth gauge # 200 mm 5870 200 072
3 / 98 To measure the axle drive housing. Various measuring
procedures.
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3 / 51 Shim # Ø 130 mm 5870 500 030

Shim # Ø 133,3 mm 5870 500 046
Measuring shaft # Ø 30 mm 5870 500 001
3 / 64 Torque spanner # 1 – 12 Nm 5870 203 031

To check the rolling resistance in the pinion bearing.
3 / 67 Adjusting screws 1 Set = 2 pcs. 5870 204 021

As assembly aid for the installation of the differential
housing.
3 / 102 Driver # EBM 5 + 1 mm 5870 048 236

To install the shaft seal 0634 319 303 into the bearing
flange 4460 328 082 .
3 / 103 Driver # 5870 056 013

To press the dust cap 4460 345 009 onto the input flange
4460 345 092 .
To be used in connection with:
Handle 5870 260 002
3 / 106 Compressed-air connection # M 12x1,5 5870 505 006

To actuate piston 4460 318 106 and adjustment of shift
fork and sliding dog resp. in the differential housing.
3 / 111 For functional testing and adjustment of the switch
0501 313 916 .
3 / 110 Indicating device 1x LED 5870 221 194

or
Multi-measuring device 5870 221 187
Universal use.
For functional testing of the switch 0501 313 916 as well
as its shift movement setting.
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3 / 137 Magnetic stand # 5870 200 055

3 / 138 Dial indicator # 5870 200 057
Universal use.
To check backlash crown gear/bevel gear.
3 / 138 Micrometer 5870 340 510

Universal use.
To check the bracket width of the axle insert.
3 / 145 Driver # 5870 048 151

With snapped in retaining ring! EBM = 3,5 + 1
To insert the shaft seal 0734 319 141 into the flange
4460 369 195.
Plastic hammer ∅ 60 mm 5870 280 004

Universal use.
To separate, join and relieve housing- and
transmission parts.
5871 209 002 W / 11

S
5870 610 002 5870 610 010 5870 281 043 5870 200 022 5870 200 067 5870 200 072
AP-17
ABTRIEB LI./RE. 140 150
SERVICE
130
110 120
100
OUTPUT L.H./R.H.
80 90
70
60
0 50
29.35
4464 014 165/167/168/169 Spezial
Werkstatthandbuch
5870 051 050 5870 050 008
5870 506 132 5870 260 004

WB / 1
5870 204 026 5870 204 023
Arbeitsmaschinen-Antriebe
5870 345 071 5870 281 058
und Achssysteme
Geschäftsbereich
5870 050 008 5870 260 004 5870 200 115 5870 401 141 5870 912 012 5870 900 015 5870 970 003 5870 230 007 5870 280 004
ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 12/2000

S
5873 012 017 5873 002 001 5870 340 510 5870 204 021 5870 221 500 5870 221 501
AP-17 = 4464 014 167 - 169
ACHSEINSATZ ,,LKST-2’’
SERVICE
DIFF. CARRIER ,,LKST-2’’
4460 028 032/034 Spezial 230 V 115 V
Blatt:/Page: 1/2
Werkstatthandbuch
5870 204 021 5870 281 013
5870 401 093 5870 900 015

WB / 2
5870 203 031 5873 002 034
5870 401 045 5873 002 001
und Achssysteme
Geschäftsbereich
90 0 10
120 130
140
150
80 20
110
70
80
90 100
70 30
0
50 60
60 50 40
29.35
5870 240 025 5870 048 236 5870 500 046 5870 500 030 5870 200 072 5870 500 001 5870 650 006 5870 200 055 5870 200 057

S
5870 204 023 5870 000 065 5870 280 004 5873 013 012 5873 003 011 5873 002 001
AP-17 = 4464 014 167 - 169
ACHSEINSATZ ,,LKST-2’’
SERVICE
DIFF. CARRIER ,,LKST-2’’
4460 028 032/034 Spezial
Blatt:/Page: 2/2
Werkstatthandbuch
5870 200 022
5870 200 066

WB / 3
150
130 140
120
110
90 100
80
60 70
50
0
29.35
5873 200 072
5873 204 010
und Achssysteme
Geschäftsbereich
5870 350 075 5870 350 077 5870 350 000 5870 350 103 5870 350 000 5870 281 047 5870 204 002 5870 000 065 5870 450 003

S
5870 506 006 5870 345 036 5870 281 047 5870 350 103 5870 350 000 5870 204 010
AP-17 = 4464 014 165
ACHSEINSATZ ,,LKZ-7’’
SERVICE
DIFF. CARRIER ,,LKZ-7’’
4460 028 033 Spezial
Blatt:/Page: 1/2
ODER/OR
Werkstatthandbuch
5870 221 194 5870 500 001
5870 221 187 5870 500 030

WB / 4
230 V
5870 221 500 5870 500 046
115 V
5870 221 501 5870 048 151
und Achssysteme
Geschäftsbereich
90 0 10
80 20
70 30
60 40
50
5870 401 045 5873 012 017 5873 002 001 5870 401 093 5870 340 510 5870 200 055 5870 200 057 5870 281 013 5870 401 148 5870 900 016

S
5870 200 066 5870 200 022 5870 200 072 5873 013 012 5873 003 011 5873 002 001
AP-17 = 4464 014 165
150 ACHSEINSATZ ,,LKZ-7’’
SERVICE
140
130

120
110
100
90
80
70
60
50
0
29.35
4460 028 033 Spezial

Blatt:/Page: 2/2
5870 000 065 5870 300 020
Repair Manual
5870 240 040 5870 000 091
WB / 5
5870 280 004 5870 200 066
150
140
130
120
110
100
90
80
70
60
50
0
29.35
5870 970 002 5870 200 072
and Axle Systems
Division
5870 240 025 5870 056 013 5870 260 002 5870 048 236 5870 204 021 5873 002 034 5873 002 001 5870 000 065 5870 203 031 5870 450 003

Division
1. OUTPUT
1.1 DISASSEMBLY
Fasten ZF-axle to the assembly truck.
(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 077
(S) Clamping braces 5870 350 075
Figure 1
Drain oil ( Figure 2 and 3 )
Output:
Loosen screw plug and cap screw (arrows) and drain oil.
Figure 2
Axle insert:
Loosen screw plugs (arrows) and drain oil from axle casing
as well as from layshaft.
Figure 3
Mark radial location of the planet carrier to the hub (arrows).

Install two adjusting screws and loosen bolted connection.
Separate planet carrier from the hub by means of the
lifting tackle.
Pay attention to released sun gear shaft!
(S) Adjusting screws 5870 204 023

(S) Lifting tackle 5870 281 058
Figure 4
1/1
Division
Snap out the retaining ring.
(S) Set of external pliers 5870 900 015
Figure 5
By means of the puller separate planet gear from planet carrier.
(S) Two-armed puller 5870 970 003
Figure 6
Loosen bolted connection and separate brake caliper from

the axle casing by means of lifting tackle.
For work to be done on the brake system, the information

and instructions of the brake manufacturer are binding!
See original instructions of the brake manufacturer!
Figure 7
If required, separate driver as well as plug shaft from the axle.
Left and right stub shafts are of different length !
Figure 8
1/2
Division
Loosen both hexagon screws and remove the lock plate

(arrow).
Figure 9
Loosen slotted nut.
Loosening torque of the slotted nut is over 2000 Nm.
(S) Slotted nut wrench 5870 401 141

(S) Centering bracket 5870 912 012
Figure 10
Remove the ring gear.
Figure 11
Squeeze out the snap ring and separate ring gear carrier from
the ring gear.
Figure 12
1/3
Division
Separate hub from the hub carrier by means of lifting tackle.
Pay attention to released bearing inner ring!
(S) Lifting bracket 5870 281 043
Figure 13
Sealing unit – hub (Figure 14 and 15):
Press shaft seal out of the hub bore.
(S) Crowbar set 5870 345 071
Figure 14
Press off the bush from the collar of the hub carrier.
Figure 15
Pull out the bearing outer ring from the hub bore (Fig. 16).
Remove ring gear-sided bearing outer ring from the bore.
Figure 16
1/4
Division
Loosen cap screws and separate brake disc from the hub
by means of the puller.
Figure 17
Loosen hexagon screws and separate hub- as well as brake

carrier from the axle casing by means of tapping.
(S) Plastic hammer 5870 280 004
Figure 18
1/5
Division
1.2 REASSEMBLY
Wet mounting face with sealing compound (Loctite,

Type No. 574).
Install two adjusting screws.
Assemble brake carrier with the collar showing to
the axle casing.
Pay attention to radial location!

Figure 19
Wet mounting face of the hub carrier with sealing compound

(Loctite, Type No. 574).
Assemble hub carrier and locate it preliminarily (do not tighten)
by means of hexagon screws (install washers).
Slotted pins (arrows) have to be flush mounted.
Pay attention to installation position of the slotted pins,

also see Fig. 21!
Figure 20
To Fig. 21:
1 = Slotted pin S 15x70

z 2 = Slotted pin S 25x70
1
2 Install slots of the slotted pins, in direction of force ↔ and
180° turned to each other, also see Detail “ Z “ !
Figure 21
Tighten hexagon screws.
Tightening torque (M18/10.9) ............. MA = 440 Nm
Figure 22
1/6
Division
Assemble brake disc and locate it preliminarily (do not tighten)

by means of cap screws (install washers).
Slotted pins (arrows) have to be flush mounted.
Then finally tighten the cap screws.
Tightening torque (M18/10.9) .......... MA = 390 Nm
Pay attention to installation position of the brake disc!

Recess (15°- chamfer) shows upwards!
Install slotted pins with the slots in circumferential direction
(direction of force)!
Figure 23
Install bearing outer ring until contact.
Install ring gear sided bearing outer ring analogously.
(S) Driver 5870 050 008

(S) Handle 5870 260 004
Figure 24
Install wheel bolts.
(S) Wheel bolt puller – basic set 5870 610 010

(S) Insert M 22 x 1,5 5870 610 002
Figure 25
Place the bearing inner ring.
Figure 26
1/7
Division
Hub sealing (Fig. 27 ... 30)

4 1
Fig. 27 shows the installation position of the hub sealing.
Fig. 28 shows the single components of the hub sealing and
the required special tool.
2 To Fig. 27:
1 = Shaft seal
2 = Bush
3 3 = Hub carrier
4 = Hub

Figure 27 Shaft seal (1), is placed into the hub bore (Fig. 29)!
Bush (2), is installed onto collar of the hub carrier (Fig. 30) !
To Fig. 28:
1 = Shaft seal
2 = (S) Driver 5870 051 050
4 2 3 = Bush
4 = (S) Press ring 5870 506 132
Only when using the specified special tool (S), the exact
installation position of the hub sealing will be obtained!
3 1
Figure 28
Install shaft seal (1).
Wet outer diameter with spirit!

Grease sealing lip!
(S) Driver 5870 051 050
Figure 29
Install bush (2).
(S) Press ring 5870 506 132
Figure 30
1/8
Division
Cautiously install the preassembled hub until contact

by means of lifting tackle.
(S) Lifting bracket 5870 281 043
Figure 31
Assemble bearing inner ring until contact.
Figure 32
Assembly ring gear carrier until contact and fasten it

by means of snap ring.
Figure 33
Assemble ring gear (assy).
Figure 34
1/9
Division
Adjust rolling moment of the wheel bearing (Fig. 35 ... 39):
Total rolling moment (wheel bearing + sealing element)

T = 20 ... 30 Nm.
For an exact determination of the rolling moment,

it is absolutely necessary to use the special tool
(S) Adjusting nut 5870 200 115!
Determine thickness of shim (Dimension „S“), see opposite

B "S"
sketch!
A
Figure 35
Unscrew adjusting nut and tighten it until the specified total

rolling moment T = 20 ... 30 Nm is obtained.
T =20 ... 30 Nm, corresponds to a traction force from 90 to

135 N, providing a hub diameter of 444 mm!
When tightening the adjusting nut, have hub rotated in both
directions several times!

(S) Spring balance 0 – 200 N 5870 230 007
Figure 36
Determine Dim. A, from the plane face of the slotted nut to the
face of the hub carrier, also see Fig. 35!
Dim. A e.g. ......................................... 17,60 mm
Then loosen the adjusting nut again and remove it.
Figure 37
Determine Dim. B (thickness of the adjusting nut).
Dim. B .................................................. 16,00 mm
Example:
Dim. A e.g. ........................................... 17,60 mm

Dim. B ................................................... - 16,00 mm
Results in shim s = 1,60 mm
Figure 38
1 / 10
Division
Assemble shim e.g. s = 1,60 mm.
Figure 39
Screw on the slotted nut with the chamfer showing to the outside
and tighten it.
Tightening torque ..................... MA = 2000 ... 2200 Nm

When tightening have the hub rotated in both directions
several times!
First tighten nut with 2000 Nm! If required, increase the
tightening torque until the slotted nut can be locked, see next
figure!
Figure 40 (S) Slotted nut wrench 5870 401 141


Then check the rolling moment once again and if required,
correct it by means of shim (Fig. 39)!
Rolling moment too low - install thinner shim.

Rolling moment too high – install thicker shim.
Install lock plate (arrow) and fasten it by means of

locking screws.
Tightening torque ............... MA = 86 Nm
Only new locking screws are allowed to be used!
Figure 41
1 / 11
Division
Install plug shaft (Fig. 42) into the differential until

contact, using the driver and an assembly mandrel (Fig. 43).
Figure 42
Figure 43
Heat planet gear (assy) and install it until contact.
Wear protective gloves – burn hazard!
Pay attention to installation position! Big radius of the

bearing inner ring must show to the shoulder of the planet
gear pin (downwards)!
Figure 44
Fasten planet gear by means of retaining ring.
Install the remaining planet gears accordingly.
Figure 45
1 / 12
Division
Adjust axial clearance of sun gear shaft 0,3 ... 0,6 mm

(Fig. 46 ... 48)
Assemble sun gear shaft until contact.
Determine Dim. I from the mounting face of the hub to the

face of the sun gear shaft.
Dim. I e.g. ........................................... 9,40 mm
(S) Straightedge 5870 200 022

(S) Digital-Depth gauge 5870 200 072
Figure 46
Measure Dim. II from the mounting face to the locating face

of the washer.
Dim. II e.g. .......................................... 4,00 mm
(S) Gauge blocks 5870 200 067
Figure 47
Example:
Dim. I e.g. ............................................ 9,40 mm

Dim. II e.g. ........................................... - 4,00 mm
Difference............................................... = 5,40 mm
required axial clearance ............ e.g. - 0,40 mm
Result = Thrust washer s = 5,00 mm
Fix thrust washer with grease into the planet carrier.
Figure 48
Assemble sun gear shaft.
Place O-Ring (arrow) into the annular groove and grease it.
Figure 49
1 / 13
Division
Assemble by means of lifting tackle the preassembled planet

carrier into the ring gear and locate it on the hub until contact.

2 1
Pay attention to radial location of the planet carrier!
Through hole in the hub (available only 1x, arrow 1) must be
in one line to the filler- or drain hole of the planet carrier
(arrow 2). Also pay attention to markings made at
disassembly!
3 Locate cap screw into the through hole.

Figure 50 Wet cap screw thread with sealing compound (Loctite, Type
No. 574)!
Then fasten planet carrier by means of hexagon screws.
Tightening torque (M16/10.9) ............. MA = 280 Nm
Provide sealing plug (arrow 3) with new O-Ring and install it.
Tightening torque ................ MA = 40 Nm
1.2.1 Mounting of the brake
Position brake caliper (assy) by means of lifting tackle and fasten

it by means of hexagon screws (install washers).
Tightening torque (M20/10.9) .............. MA = 560 Nm
For work to be done on the brake system, the information

and instructions of the respective brake manufacturer as well
as the vehicle manufacturer are binding!
See original instructions of the brake manufacturer!
Figure 51
1 / 14
5870 200 066 5870 200 022 5870 200 072 5873 013 012 5873 003 011 5873 002 001
AP-17 = 4464 014 165
140 150
130
90
100 110
120
ACHSEINSATZ ,,LKZ-7’’
70 80
60
0 50
29.35
4460 028 033 Spezial
S SERVICE
Blatt:/Page: 2/2
5870 000 065 5870 300 020
5870 240 040 5870 000 091
WB / 5
5870 280 004 5870 200 066
140 150
130
110 120
100
90
70 80
60
0 50
29.35
Werkstatthandbuch
5870 970 002 5870 200 072

und Achssysteme
Geschäftsbereich
5870 240 025 5870 056 013 5870 260 002 5870 048 236 5870 204 021 5873 002 034 5873 002 001 5870 000 065 5870 203 031 5870 450 003

Division
2. ZF – AXLE INSERT
Type: LKST - 2
2.1 DIASSEMBLY
Drain oil (Fig. 1 and 2 )
Output:
Loosen screw plug as well as cap screw (arrows) and drain oil.
Figure 1
Axle insert/axle casing
Loosen screw plugs (arrows) and drain oil from axle casing
as well as from layshaft.
Figure 2

Prior to separate the axle insert from the axle casing
both plug shafts have to be removed, also see Chapter 1!
Loosen bolted connection and separate axle insert by means

of lifting tackle and back-off screws from the axle casing.

(S) Back-off screws 5870 204 010
Figure 3
2.1.1 Axle drive housing - Differential
Fasten axle insert to the assembly truck.

Loosen bolted connection (crown gear-differential cage)
and remove locking screws.

(S) Clamping ring 5870 350 103
Figure 4
2/1
Division
Press off the slotted pin and loosen slotted nut.
Figure 5
Loosen hexagon screws and remove bearing bracket.
Hexagon screws are locked with Loctite!

Heat axle drive housing around the threaded holes!
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501
Figure 6
Separate the differential by means of lifting tackle from

the axle drive housing.
(S) Gripping tongs 5870 281 013
Figure 7
Remove both bearing inner rings (differential bearing).
Bearing HM 516 449

(S) Gripping insert 5873 012 017
(S) Basic set 5873 002 001
Bearing JH 716 649

(S) Reducer 5873 003 011
(S) Basic set 5873 002 001
Figure 8
2/2
Division
Loosen both cap screws.

Take off the housing cover and remove single components.
Figure 9
2.1.2 Layshaft
Loosen bolted connection and separate layshaft housing from

the axle drive housing by means of the lifting tackle.

(S) Eye bolt assortment 5870 204 002
Figure 10
Fasten layshaft housing to the assembly truck.

Figure 11
Rotate housing by 90°.

Loosen slotted nut and remove the input flange.
Slotted nut is locked with Loctite!

Heat slotted nut before loosening (approx. 120° C)!
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501
(S) Fixture 5870 240 025
Figure 12
2/3
Division
Loosen hexagon screws and separate sealing holder

from the housing cover.
Figure 13
Squeeze out retaining ring and remove support shim.
Figure 14
Press the drive shaft out of the bearing.
(S) Extractor 5870 000 065
Figure 15
Remove the adjusting ring (Figure) and press the

bearing inner ring from the shaft.
Figure 16
2/4
Division
Remove bearing inner ring and spacer ring.
Figure 17
Loosen hexagon screws and separate cover from the housing.
Figure 18
Remove spur gear.
Figure 19
2/5
Division
Fasten spur gear by means of support sheet.

Do not use hardened material!
(S) Magnetic block 5870 450 003
Figure 20
Heat slotted nut.
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501
Figure 21
Loosen slotted nut.
Figure 22
Press the input pinion out of the bearing and remove

released bearing inner ring.
(S) Extractor 5870 000 065
Figure 23
2/6
Division
Pull off the bearing inner from the input pinion.

(S) Basic set 5873 002 001
Figure 24
Remove adjusting ring and spacer bush.
Figure 25
Align spur gear (arrow) centrally to the bearing bush and

press single components out of the housing bore.
(S) Extractor 5870 000 065
Figure 26
Press out the bearing outer ring from the bearing bush
and remove the released shim.
Figure 27
2/7
Division
2.2 REASSEMBLY
2.2.1 Layshaft
Press bearing outer ring (pinion bearing) into the housing bore
until contact.
Figure 28
Turn the housing.
Press in the bearing outer ring (input pinion bearing) until

contact.
Figure 29
Insert spur gear into the housing bore.
Pay attention to the installation position - inner diameter

85 mm, is showing downwards!
Figure 30
Press the bearing bush into the housing bore until contact.
Pay attention that the bearing bush is located perfectly!
Figure 31
2/8
Division
Setting of contact pattern – crown gear set (Fig. 32 ... 37)
Make the following steps with the utmost precision!
Layshaft housing:
Measure Dim. a, from the mounting face to the locating face
of the bearing outer ring.
Dim. a e.g. ............................................... 29,70 mm

(S) Measuring ledge 5870 200 022
Figure 32 (S) Digital-Depth gauge 5870 200 072
Axle drive housing
Put shims (2x, see arrows) into the bearing bores and
assemble the measuring shaft.
(S) Shims 5870 500 030

(S) Shims 5870 500 046
(S) Measuring shaft 5870 500 001
Figure 33
Determine Dim. b, from the mounting face to the measuring

shaft.
Dim. b e.g. ............................................. 196,75 mm
Example A1
Dim. a ...................................................... 29,70 mm

Dim. b ...................................................... + 196,75 mm
Dim. c (1/2 ∅ Measuring shaft) ............... - 15,00 mm
results in Dim. X (housing dim.) 241,45 mm
Figure 34
Measure Dim. d (bearing height).
Dim. d e.g. ........................................... 42,70 mm

Figure 35
2/9
Division
198 – 0,1 Read Dim. e (pinion dim.).
Dim. e e.g. (198 – 0,1) .......................... 197,90 mm
Example A2
Dim. d .................................................. 42,70 mm

Dim. e .................................................. + 197,90 mm
results in Dim. Y (Install. dim.) = 240,60 mm
Figure 36
Example A3
Dim. X ............................................... 241,45 mm

Dim. Y ............................................... - 240,60 mm
Difference ^ Shim s = 0,85 mm
Put the shim e.g. s = 0,85 mm into the bearing bush.
Figure 37
Undercool bearing outer ring and install it until contact.
Wear protective gloves!
Figure 38
Press bearing inner ring over the shaft of the input pinion
until contact.
Figure 39
2 / 10
Division
Assemble input pinion.

Figure 40
By means of fixture the input pinion is to be fastened axially,

see figure.
Then rotate housing by 180°.
(s) Extractor 5870 000 065
Figure 41
Rolling moment of the pinion bearing

Adjust TRi = 3,5 ... 4,0 Nm (Fig. 42 ... 46)
As per experience the required rolling moment is obtained

by use of the adjusting ring (e.g. s = 7,55 mm) available at
disassembly!
However, a later checking of the rolling moment is
imperative!
Assemble spacer bush with the small collar showing upwards

(arrow) into the bore of the spur gear and install the adjusting
ring (e.g. s = 7,55 mm).
Figure 42
Heat bearing inner ring and assemble it until contact.
After cooling-down of the bearing inner ring the pinion

fastening has to be removed again (Fig. 41).
Figure 43
2 / 11
Division
Fasten spur gear by means of supporting block.
(S) Magnetic blocks 5870 450 003
Figure 44
Assemble intermediate washer and install slotted nut.
Wet thread of the slotted nut with Loctite, Type No. 649!
When tightening have the pinion rotated in both directions
several times!
Tightening torque ........................ MA = 1200 Nm
Figure 45
Determine rolling moment of the pinion bearing.
TRi e.g. 3,5 Nm
If the required rolling moment TRi = 3,5 ... 4 Nm differs,

it is to be corrected with the corresponding adjusting ring
(Fig. 42)!
(S) Torque spanner 5870 203 031
Figure 46
Install spur gear.
Figure 47
2 / 12
Division
Assemble drive shaft.
Figure 48
Preliminarily fasten the drive shaft axially by means of a fixture.
(S) Extractor 5870 000 065
Figure 49
Assemble spacer ring with the collar showing downwards.
Figure 50
Heat bearing inner ring and assemble it until contact.
Figure 51
2 / 13
Division
Assemble the support shim and snap in the retaining ring

(Fig. 52)
Then remove the drive shaft fastening (Fig. 49) again.
Figure 52
By means of the fixture press the drive shaft downwards until

the support shim is located on the retaining ring.
Fixture is to be removed only when the opposite bearing

inner ring (Fig. 58) has been installed!
(S) Extractor 5870 000 065
Figure 53
Press the bearing outer ring into the housing cover

until contact.
Figure 54

Type No. 574).

Make the following steps (Fig. 55 to 60) in an immediate
sequence to avoid that the sealing compound gets hardened!
Figure 55
2 / 14
Division
Put on the housing cover and install it preliminarily

until contact by means of locking screws.
Use new locking screws!

Slotted pin is to be flush mounted (Figure)!
Then tighten the locking screws.
Tightening torque ...................... MA = 155 Nm
Figure 56
Rolling moment of drive shaft bearing

Adjust TAn = 1,5 ... 3 Nm (with shaft seal) (Fig. 57 ... 64)

disassembly!
However, a later checking of the rolling moment is
imperative!
Install adjusting ring (e.g. s = 23,70 mm).
Figure 57
Heat bearing inner ring and install it until contact.

After cooling down of the bearing inner ring remove
the drive shaft fastening (Fig. 53)!
Figure 58

Type No. 574).
Figure 59
2 / 15
Division
Fasten sealing holder by means of locking screws.
Tightening torque ...................... MA = 155 Nm
Figure 60
Install the shaft seal with the sealing lip showing

to the oil chamber.
+1

Installation depth 5 mm! By use of the specified driver (S)
the exact installation position will be obtained!
Wet outer diameter with sealing compound
(Loctite, Type No. 574)!
(S) Driver 5870 048 236
Figure 61
Press dust cap until contact.
Figure 62
Assemble input flange.
Figure 63
2 / 16
Division
Assemble washer and tighten slotted nut.
Tightening torque ........................... MA = 750 Nm

Wet thread of the slotted nut with Loctite (Type No. 649)!
Wet contact faces of the washer with sealing compound
Loctite (Type No. 574)!
When tightening have the drive shaft rotated in both
direction several times!

Figure 64 (S) Fixture 5870 240 025
Total rolling moment (pinion + drive shaft).
Ttot e.g. 5,5 Nm.
Example „B“:
Ttot (Pinion + Drive shaft) e.g. ......................... 5,5 Nm

TPinion (Pinion, see Page 2.12/Fig. 46) ................. - 3,5 Nm
results in TAn (drive shaft) = 2,0 Nm

Figure 65
If the required rolling moment of the drive shaft
TAn = 1,5 ... 3,0 Nm differs, it is to be corrected with the
corresponding adjusting ring (Fig. 57)!
Wet mounting face with sealing compound Loctite

(Type No. 574)
Figure 66
Install the preassembled layshaft housing by means of the

lifting tackle to the axle drive housing until contact.

Figure 67
2 / 17
Division
Preliminarily fix the layshaft housing by means of

locking screws and flush-mount both slotted pins (arrows).
Then tighten the locking screws
Tightening torque ....................... MA = 155 Nm
Figure 68
2 / 18
Division
2.2.2 DIFFERENTIAL DL-2400, Locking value 45%
The following exploded view shows the single components of the differential and their installation position.
1 = Tension bolts 7 = Pressure ring

2 = Housing cover 8 = Axle bevel gear
3 = Thrust washer (steel) 9 = Diff. bevel gear
4 = Thrust washer (brass) 10 = Differential axle
5 = Outer clutch disc (optional) 11 = Differential housing
6 = Inner clutch disc A = Disc set
B = Disc set
Fig. 69
In order to adjust the assembly clearance of the internal components (see Fig. 79 ... Example C), outer clutch discs (5)
of varying thickness are available (s = 2,7 ... 3,3 mm)!
For this reason the outer clutch discs have to be selected in such a way that the height of the disc sets A and B is
compensated identically on both sides!
Heat crown gear and install it on the differential housing until

contact.
Figure 70
2 / 19
Division
Prior to start assembling, oil single components acc. to ZF

Lists of Lubricants TE-ML 05 (with LS-Additive)!
Place both thrust washers into the differential cage.
Install brass thrust washer showing to the axle bevel gear

(top)!
Figure 71
Install disc set A, beginning with one outer clutch disc.
As per experience the required assembly clearance is

obtained by installing two outer clutch discs of the thickness
s = 3,3 mm!
Also pay attention to instructions, Page 2/19!
Figure 72
Assemble pressure ring.
Figure 73
Assemble axle bevel gear until both inner clutch discs

are located.
Figure 74
2 / 20
Division
Install the differential spider assy.
Figure 75
Install the second axle bevel gear.
Figure 76
Figure 77
Install disc set B, beginning with one inner clutch disc.

s = 3,3 mm!
Figure 78
2 / 21
Division
Check assembly clearance of internal components

= 0,2 ... 0,6 mm (Fig. 79 ... Example „C“):
Differential housing:
Press outer plate evenly on and measure Dim. I, from the

mounting face to the outer plate.
Dim. I e.g. .............................................. 4,30 mm
Figure 79
Housing cover:
Determine Dim. II from the contact face to the mounting face.
Dim. II e.g. .......................................... 4,00 mm
Figure 80
Example „C“
Dim. I e.g. ............................................. 4,30 mm

Dim. II e.g. ........................................... - 4,00 mm
Difference ^ Assembly clearance = 0,30 mm
For installation of new clutch discs the lower value of the

required assembly clearance should be aimed at!
Corrections have to be made with the respective outer clutch
discs!
Place both thrust washers with assembly grease into the

housing cover.
Install brass thrust washer showing to the

axle bevel gear (top)!
Figure 81
2 / 22
Division
Fasten housing cover with two cap screws.
Tightening torque (M10/8.8) ................... MA = 46 Nm
Figure 82
Press bearing inner ring until contact.

Install crown gear-sided bearing inner ring analogously.
Figure 83
Position the differential by means of lifting tackle in the

axle drive housing and install both bearing outer rings.
Figure 84
Install both adjusting nuts.
Figure 85
2 / 23
Division
Locate the bearing bracket and fasten it preliminarily by means

of hexagon screws (install the washers).
Wet the thread of the hexagon screws with Loctite (Type No.
649)!
Pay attention to an exact coverage of the threaded parts
(axle drive housing, adjusting nut and bearing bracket)!
Figure 86
Rotate the axle drive housing by 90°.

Figure 87
Fasten housing cover, differential cage and crown gear by means

of locking screws.
Tightening torque (M16x1,5/12.9) ............. MA = 390 Nm
Figure 88
2 / 24
Division
Adjust Backlash – Crown gear set = 0,27 ... 0,33 mm,

Bearing rolling moment-Differential bearing
T = 3.0 ... 4.0 Nm
and
Bracket dimension = 358 –0,1 mm (Fig. 89 und 90):
Determine the backlash by alternately setting of both adjusting

nuts (Fig. 89).
Setting of the adjusting nuts must be made without the

application of force!
Differential bearing is not yet allowed to be preloaded,
Figure 89 however, has to be absolutely backlash-free! In order to
ensure this, rotate the differential several times during the
setting procedure!
Determine the bearing rolling moment and the bracket

dimension by further tightening of both adjusting nuts.
As per experience the required bearing rolling moment as

well as the bracket dimension are obtained at further
tightening both adjusting nuts by 1 – 2 notches each.
Check bracket dimension (Fig. 90) once again and correct it,
if required!
(S) Magnetic stand 5870 200 055

Figure 90
(S) Dial indicator 5870 200 057
(S) Micrometer 5870 340 510
Check contact pattern – Crown gear set (Fig. 91 and 92)
Ink mark some driving and coasting flanks.
Figure 91
Roll the crown gear over the input pinion in both directions
several times.
Compare the contact pattern obtained with the contact pattern
examples Page 0.6 and 07.
If the contact pattern differs, there has been a measuring

error at determination of the shim (Page 2/9 ... 2/10) which is
imperative to be corrected!
Figure 92
2 / 25
Division
Fasten adjusting nut by means of slotted pin (arrow).
Figure 93
Install set screws (4x, see Arrows).
Wet screw-in thread (length 20 mm) with Loctite,

Typ-No. 262 !
Figure 94
Wet mounting face with sealing compound Loctite, (Type No.

574).
Bild 69
Position differential carrier by means of lifting device on the

axle unit contact is obtained, and fasten by means of locking
screws and hex. nuts.
Tightening torque (Locking screws) ................ MA = 375 Nm

Tightening torque (Hexagon nut) .................... MA = 280 Nm
Then install the plug shafts, also see Chapter 1!

Bild 70
2 / 26
Division
3. ZF – AXLE INSERT
Type: LKZ-7
3.1 DISASSEMBLY
Drain oil (Figure 1 and 2):
Output:
Loosen screw plug as well as cap screw (arrows) and drain oil.

Figure 1 (S) Holding fixture 5870 350 077
(S) Clamping braces 5870 350 075
Axle insert/axle casing:
Loosen screw plugs (arrows) and drain oil from axle casing,
layshaft as well as differential housing.
Figure 2
3.1.1 Flange Shaft
Loosen cap screws and by means of extractor separate

flange shaft from the axle casing.
(S) Counter support 5870 300 020

(S) Extractor 5870 000 091
Figure 3
Squeeze out retaining ring and remove released shims.
(S) Set of pliers 5870 900 016
Figure 4
3/1
Division
Press off flange as well as ball bearing from the shaft.
Figure 5
Press shaft seal out of the flange.
Figure 6

Prior to separate the axle insert from the axle casing
both plug shafts have to be removed, also see Chapter 1!
Left and right plug shaft are of a different length!
Loosen bolted connection and separate axle insert by means

of lifting tackle and back-off screws from the axle casing.
(S) Back-off screws 5870 204 010

Figure 7
Fasten axle insert to the assembly truck.

Figure 8
3/2
Division
3.1.2 Axle drive housing – Differential
Loosen bolted connection (crown gear-differential cage)

and remove locking screws.
Figure 9
Press off the slotted pin and loosen slotted nut.
(S) Pry bar set 5870 345 036
Figure 10
Loosen hexagon screws and remove bearing bracket.
Hexagon screws are locked with Loctite!

Heat axle drive housing around the threaded holes!
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115V 5870 221 501
Figure 11
Separate the differential by means of lifting tackle from

the axle drive housing.
Figure 12
3/3
Division
Remove both bearing inner rings (differential bearing).
Bearing HM 516 449

(S) Basic set 5873 002 001
Bearing JH 716 649

(S) Reducer 5873 003 011
(S) Basic set 5873 002 001
Figure 13
Loosen both cap screws.

Take off housing cover and remove the single components.
Figure 14
3.1.3 Layshaft – Interaxle Differential
Loosen bolted connection and separate layshaft housing from

the axle drive housing by means of the lifting tackle.
(S) Lifting chain 5870 281 047

Figure 15
Fasten housing to the assembly truck.

Figure 16
3/4
Division
Heat slotted nut (approx. 120° C).
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 17
Loosen slotted nut.

(S) Fixture 5870 240 025
Figure 18
Preliminarily fix the input flange by means of slotted nut.

By means of lifting tackle separate the interaxle differential
with bearing cover from the housing.

(S) Eye bolts 5870 204 002
Figure 19
Remove the input flange.

Press the differential out of the bearing flange.
Figure 20
3/5
Division
Separate the bearing flange from the intermediate flange.
Pay attention to released shim(s)!
Figure 21
Press the ball bearing out of the intermediate flange.
Pay attention to the released shim(s)!
Figure 22
Pull off the bearing inner ring from the differential cage.
(S) Two-armed puller 5870 970 002
Figure 23
Loosen cap screws and remove released single components.
Figure 24
3/6
Division
Loosen hexagon screws evenly and separate cylinder

from the housing.
Figure 25
Remove switch (1) and sliding pin (2).
2
1
Figure 26
Loosen locking screws and remove both bearing pins.
Figure 27
Remove shift fork and piston (arrow).
Figure 28
3/7
Division
Loosen counternut and remove adjusting screw.
Figure 29
Loosen slotted nut (spur gear bearing) see Figure 30 ... 32!
(S)
Fasten hollow shaft by means of fixture (S).
(S) Locking device 5870 240 040
Figure 30

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 31
Loosen slotted nut.
Then remove fixture (Figure 30) again.
Figure 32
3/8
Division
Press out the hollow shaft from the bearing.
(S) Extractor 5870 000 065
Figure 33
Take off the adjusting ring.
Figure 34
Support hollow shaft on the sliding dog and press of the

bearing inner ring from the shaft.
Figure 35
Remove bearing inner ring and spacer ring.
Figure 36
3/9
Division
Loosen locking screws and by means of lifting tackle separate

differential housing from the layshaft housing.

(S) Pry bar set 5870 345 036
Figure 37
Remove spur gear.
Figure 38

(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 39
Fasten spur gear by means of supporting block (arrow).
Loosen slotted nut.

(S) Magnetic block 5870 450 003
Figure 40
3 / 10
Division
Press the input pinion out of the bearing and remove

released bearing outer ring.
(S) Extractor 5870 000 065
Figure 41
Pull off the bearing inner from the input pinion.

(S) Basic set 5873 002 001
Figure 42
Remove adjusting ring and spacer bush.
Figure 43
Align spur gear (arrow) centrally.

Put fixture on the spur gear and press out the bearing bush
from the housing bore.
(S) Extractor 5870 000 065
Figure 44
3 / 11
Division
Press out the bearing outer ring from the bearing bush
and remove the shim.
Figure 45
3 / 12
Division
3.2 REASSEMBLY
3.2.1 Layshaft
Press bearing outer ring (pinion bearing) into the housing bore
until contact.
Figure 46
Turn the housing.
Press in the bearing outer ring (input pinion bearing) until con-
tact.
Figure 47
Put the spur gear into the housing bore.
Pay attention to installation position - inner diameter

85 mm shows downwards!
Figure 48
Press the bearing bush into the housing bore until contact.
Pay attention that the bearing bush is located perfectly!
Figure 49
3 / 13
Division
Setting of contact pattern – crown gear set (Fig. 50 ... 55)
Make the following steps with the utmost precision!
Layshaft housing:
Measure Dim. a, from the mounting face to the locating face
of the bearing outer ring.
Dim. a e.g. ............................................... 29,70 mm

(S) Straightedge 5870 200 022
Figure 50 (S) Digital-Depth gauge 5870 200 072
Axle drive housing
Put shims (2x, see arrows) into the bearing bores and
assemble the measuring shaft.
(S) Shims 5870 500 030

(S) Shims 5870 500 046
(S) Measuring shaft 5870 500 001
Figure 51
Determine Dim. b, from the mounting face to the measuring

shaft.
Dim. b e.g. ............................................. 196,75 mm
Example A1
Dim. a ...................................................... 29,70 mm

Dim. b ...................................................... + 196,75 mm
Dim. c (1/2 ∅ Measuring shaft) ............... - 15,00 mm
results in Dim. X (housing dim.) 241,45 mm
Figure 52
Measure Dim. d (bearing height).
Dim. d e.g. ........................................... 42,70 mm

Figure 53
3 / 14
Division
Read Dim. e (pinion dim.).

198 – 0,1
Dim. e e.g. (198 – 0,1) .......................... 197,90 mm
Example A2
Dim. d .................................................. 42,70 mm

Dim. e .................................................. + 197,90 mm
results in Dim. Y (Install. dim.) = 240,60 mm
Figure 54
Example A3
Dim. X ............................................... 241,45 mm

Dim. Y ............................................... - 240,60 mm
Difference ^ Shim s = 0,85 mm
Put the shim e.g. s = 0,85 mm into the bearing bush.
Figure 55
Undercool bearing outer ring and install it until contact.
Figure 56
Press bearing inner ring over the shaft of the input pinion
until contact.
Figure 57
3 / 15
Division
Assemble input pinion.

Figure 58
Install input pinion axially by means of fixture.
(S) Extractor 5870 000 065
Figure 59
Adjust rolling moment of the TRi = 3,5 ... 4,0 Nm

(Figure 60 ... 64):

disassembly!
However, a later checking of the rolling moment is manda-
tory!
Assemble spacer bush with the small collar showing upwards

(arrow) into the bore of the spur gear and install the adjusting
ring (e.g. s = 7,55 mm)!
Figure 60
After cooling-down of the bearing inner ring the pinion

fastening (Fig. 59) has to be removed again.
Figure 61
3 / 16
Division
Fix spur gear radially by means of supporting block (arrow).
Do not use hardened materials!
(S) Magnetic blocks 5870 450 003
Figure 62
Assemble intermediate washer and install slotted nut.
Wet thread of the slotted nut with Loctite, Type No. 649!
When tightening have the pinion rotated in both directions
several times!
Tightening torque ........................ MA = 1200 Nm
Figure 63
Determine rolling moment of the pinion bearing.
TRi e.g. 3,5 Nm
If the required rolling moment TRi = 3,5 ... 4 Nm differs,

it is to be corrected with the corresponding adjusting ring
(Figure 60)!
(S) Torque spanner 5870 203 031
Figure 64
Install the spur gear.
Figure 65
3 / 17
Division
Install the bearing outer ring into the bore of the

interaxle differential housing until contact.
Figure 66

Type No. 574).
Figure 67
Install the differential housing by means of lifting tackle to

the layshaft housing until contact.

Figure 68
Insert the slotted pin (arrow) and the housing by means

of locking screws.
Tightening torque (6 pcs., M12x30/12.9) ... MA = 155 Nm

Tightening torque (10 pcs., M12x35/12.9) ... MA = 155 Nm

Install new locking screws!
Figure 69
3 / 18
Division
Guide sliding dog over the gearing of the hollow shaft.
Dog-type gearing shows downwards!
Figure 70
Press tapered roller bearing over the hollow shaft until

contact.
Figure 71
Place spacer ring s = 23,3 mm (constantly) upon the spur gear.
Figure 72
Assemble hollow shaft until contact.
Figure 73
3 / 19
Division
Fasten hollow shaft by means of fixture (S).

(S)
(S) Locking device 5870 240 040

The locking device is necessary to allow the later
tightening of the slotted nut (Figure 77)!
Figure 74
Adjust rolling moment of the hollow shaft bearing THo = 0,5

... 2,0 Nm (Figure 75 ... 78)

disassembly!
However, a later checking of the rolling moment is manda-
tory!
Assemble adjusting ring (optional) e.g. s = 12,9 mm.
Outer diameter 96 mm, shows to the spur gear (downwards)!
Figure 75
Figure 76
After cooling down of the bearing inner ring, install slotted nut.
Tightening torque ......................... MA = 1200 Nm

When tightening have the hollow shaft rotated in both
directions several times!
Figure 77
3 / 20
Division
Remove the locking device (see Figure 74) again.
Determine the overall rolling moment (pinion + hollow shaft).

Tges e.g. ..... 4,5 Nm.
Example „B“:
Tges (Pinion + Hollow shaft) e.g. .................. 4,5 Nm

TRi (Pinion, see Page 3.17) e.g. ................... - 3,5 Nm
Results in THo (hollow shaft bearing) .......... = 1,0 Nm
Figure 78
If the required rolling moment is not obtained, THo = 0,5 ...

2,0 Nm, is to be corrected with the respective adjusting
ring (Figure 75)!
3.2.2 Interaxle differential

1 X
Install both sliding pads (arrows).

Driver (1) is not located centrally, X=short side.
Pay attention to installation position, see next figure!
Figure 79
X Assemble shift fork into sliding dog.
Pay attention to location, also see Figure 79!
Figure 80
3 / 21
Division
To Figure 81 :
1 = U-ring
2 = Compression spring
3 = Piston
Assemble U-ring into the annular groove and install the

compression spring.
3
2
Pay attention to the location of the U-ring – sealing lip,
see arrow!
1
Figure 81
Put centering ring (arrow) into the recess.
Install preassembled piston.
Pay attention to radial location of the piston, see figure!

Oil U-ring!
Figure 82
Assemble O-rings (arrows), position the shift fork and fix it

by means of pins.
Then fix both pins by means of locking screws.
Tightening torque ......................... MA = 45 Nm
Figure 83

Type No.574).
Assemble cylinder and fasten it evenly by means of

hexagon screws.
Pay attention to radial location, see mounting hole

(arrow) !
Tightening torque (M8/8.8) ........... MA = 23 Nm
Figure 84
3 / 22
Division
Preassemble differential (Figure 85 ... 89).
Prior to start assembly the single components have

to be oiled acc. to ZF List of Lubricants TE-ML 05!
Place the thrust washer with the lubrication groove all

around showing upwards.
Figure 85
Fix thrust washer axially by means of grooved pins (arrows).
Pay attention to the installation depth of the grooved pins!

The face of the grooved pins must be insignificantly
below the contact face/thrust washer!
Figure 86
Assemble axle bevel gear.
Figure 87
Pay attention to the radial location of the thrust washers –

secure against rotation in horizontal position, see arrow!
Figure 88
3 / 23
Division
Put on the differential cage half and fasten it with cap screws.
Pay attention to radial location, see ZF No.!

Tightening torque (M12/10.9) ............... MA = 115 Nm
ZF-No.:
Figure 89
Adjust backlash – interaxle differential

= 0,18 ... 0,23 mm (Figure 90 ... 92).
Install the preassembled differential.
Determine Dim. I from the housing mounting face to

the locating face/ball bearing.
Dim. I e.g. ........................................ 5,0 mm
Figure 90
Take several measuring points and determine mean value!
Intermediate flange:
Measure Dim. II from the mounting face to the locating face/

ball bearing.
Dim. II e.g. ......................................... 6,7 mm
Example „C“:
Dim. II e.g. .......................................... 6,70 mm

Dim. I e.g. ........................................... - 5,00 mm
Intermediate result .............................. = 1,70 mm
Figure 91 Axial dimension (empirical value) ........ + 0,20 mm
Result = Shim(s) s = 1,90 mm

The required backlash = 0,18 ... 0,23 mm is obtained by
axial displacement of the differential (+ 0,20 mm, see
example „C“)!
Place the determined shim into the intermediate flange.
Figure 92
3 / 24
Division
Press in the ball bearings until contact.
Figure 93
Put in both bearing inner rings.

Put preassembled intermediate flange upon the differential
and press in the ball bearing until contact.
Locate press bush on the bearing inner ring!
Figure 94
Heat housing bore.
Make the following steps (Figure 95 ... 101) immediately

to avoid hardening of the sealing compound!
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Figure 95

Type No. 574).
Figure 96
3 / 25
Division
Install adjusting screws.

Install intermediate flange until contact.
Figure 97
Adjust ball bearing backlash-free (Figure 98 ... 100)
Measure Dim. I from face of the ball bearing to the

mounting face.
Dim. I e.g. .............................................. 10,40 mm
(S) Digital-Depth dimension 5870 200 072
Figure 98
Bearing flange:
Measure Dim. II from mounting face to contact face of the

ball bearing.
Dim. II e.g. .......................................... 11,10 mm
Example „D“:
Dim. II e.g. .............................................. 11,10 mm

Dim. I e.g. ............................................... - 10,40 mm
Difference = Shim s = 0,70 mm
Figure 99
Place shim with assembly grease into the bearing cover.
Figure 100
3 / 26
Division

Type No. 574).
Assemble bearing cover and fasten it with locking screws.
Tightening torque (M12x45/12.9) .............. MA = 155 Nm
Figure 101
Install shaft seal with the sealing lip showing to the oil chamber.
(S)
By use of the specified driver (S) the exact installation
position will be obtained!
Depending on the version varying shaft seals can be used:

Outer diameter rubber-coated – wet with spirit;
Outer diameter metallic – wet with sealing compound
(S) Driver 5870 048 236
Figure 102
Press dust cap upon the input flange until contact.
(S) Driver 5870 056 013

(S) Handle 5870 260 009
Figure 103
Assemble input flange and place the washer.
Figure 104
3 / 27
Division
Install slotted nut.
Tightening torque .................................. MA = 1000 Nm


(S) Fixture 5870 240 025
Figure 105
Adjust sliding dog (differential lock) to be free of pressure

(Picture 106 ... 108)
Install compressed-air connection (S), see arrow!
(S) Compressed-air connection 5870 505 006
Pressurize piston with compressed air (max. 10 bar) and make

sure by rotating on the input flange that the differential lock is
shifted (Figure 106).
Then wet some turns of the adjusting screw with sealing com-
Figure 106 pound (Loctite, Type No. 574) and fasten adjusting screw by
hand until contact (piston rod) (Picture 107).
By further tightening of the adjusting screw by approx. 1/3 turn

the sliding dog is free of pressure (Figure 108).
Then lock the adjusting screw by means of hexagon nut.
Figure 107
Figure 108
3 / 28
Division
Adjust pressure switch (differential lock) (Figure 109 ... 111)
To sketch 109:
1 = Pressure switch
2 = Sealing ring (Cu)
3 = Sliding pin (optional)
3
1
2
Sliding pin length, e.g. 16,5 mm (empirical value) is
determined by the On-/Off function of the pressure switch!
Figure 109
Install sliding pin, sealing ring and pressure switch.

Then connect the measuring device (arrow).
(S) Indicating device 5870 221 194

or
(S) Multi-measuring device 5870 221 187
Figure 110
Pressurize piston by means of compressed air (max. 10 bar) and

make sure by turning on the input flange that the differential lock
is shifted.
Current flow (warning lamp is lighting) is only admissible in

end position! This means the gearing of the sliding dog must
be engaged completely!
A lighting-up of the warning lamp if the sliding dog is not
fully engaged is not admissible!
If required, correct it with the corresponding sliding pin
(Pos. 3 /Figure 109)!
Figure 111
3 / 29
Division
To sketch 112:
1 = Perforated sheet
2 = Filter insert
1
2
Figure 112
Place perforated sheet into the cylinder bore (arrow) and

install filter insert.
Seal threaded hole by means of screw plug

(Pöppelmann) until installation of the pressure line!
Figure 113

Type No. 574).
Figure 114
By means of lifting tackle locate the preassembled layshaft

housing on the axle drive housing.

Figure 115
3 / 30
Division
Both slotted pins (arrows) have to be flush-mounted and

layshaft housing is to be fixed with locking screws.
Tightening torque ........................... MA = 155 Nm
Figure 116
3 / 31
Division
3.2.3 DIFFERENTIAL DL-2400, Locking value 45%
The following exploded view shows the single components of differential and their installation position.
1 = Locking screws 7 = Pressure ring

2 = Housing cover 8 = Axle bevel gear
3 = Thrust washer (steel) 9 = Diff. bevel gear
4 = Thrust washer (brass) 10 = Differential axle
5 = Outer clutch disc (optional) 11 = Differential housing
6 = Inner clutch disc A = Disc set
B = Disc set
Figure 117
In order to adjust the assembly clearance of the internal components (see Fig. 127 ... Example C), outer clutch discs
(5) of varying thickness are available (s = 2,7 ... 3,3 mm)!
For this reason the outer clutch discs have to be selected in such a way that the height of the disc sets A and B is com-
pensated identically on both sides!
Heat crown gear and install it on the differential housing

until contact.
Figure 118
3 / 32
Division
Prior to start assembly, oil single components acc. to ZF List

of Lubricants TE-ML 05 (with LS-Additive)!
Place both thrust washers into the differential cage.
Install brass thrust washer showing to the axle bevel

gear (top)!
Figure 119
Install disc set A, beginning with an outer clutch disc.

s = 3,3 mm! Also pay attention to instructions, Page 3/32!
Figure 120
Figure 121
Assemble axle bevel gear until both inner clutch discs are
located.
Figure 122
3 / 33
Division
Figure 123
Install the second axle bevel gear.
Figure 124
Figure 125
Install disc set B, beginning with one inner clutch disc.

s = 3,3 mm! Also pay attention to instructions, Page 3/32!
Figure 126
3 / 34
Division
Check assembly clearance of internal components

= 0,2 ... 0,6 mm (Fig. 127 ... Example „E“):
Differential housing:
Press on outer clutch disc and measure Dim. I from the

mounting face to the outer clutch disc.
Dim. I e.g. .............................................. 4,30 mm
Figure 127
Housing cover:
Determine Dim. II from the contact face to the mounting face.
Dim. II e.g. .............................................. 4,00 mm
Figure 128
Example „E“
Dim. I e.g. ............................................. 4,30 mm

Dim. II e.g. ........................................... - 4,00 mm
Difference ^ Assembly clearance = 0,30 mm
For installation of new clutch discs the lower value of the

required assembly clearance should be aimed at!
Corrections have to be made with the respective outer clutch
discs!
Place both thrust washers with assembly grease into the

housing cover.
Install brass thrust washer showing to the axle bevel

gear (top)!
Figure 129
3 / 35
Division
Fasten housing cover with two cap screws.
Figure 130
Press bearing inner ring until contact.

Install crown gear-sided bearing inner ring analogously.
Figure 131
Position the differential by means of lifting tackle in the

axle drive housing and install both bearing outer rings.
Figure 132
Install both adjusting nuts.
Figure 133
3 / 36
Division
Locate the bearing bracket and fasten it preliminarily by means

of hexagon screws (install the washers).
Wet the thread of the hexagon screws with Loctite (Type

No. 649)!
Pay attention to an exact coverage of the threaded parts
(axle drive housing, adjusting nut and bearing bracket)!
Figure 134
Rotate the axle drive housing by 90°.
Tightening torque (M18/10.9) ................ MA = 390 Nm
Figure 135
Fasten housing cover, differential cage and crown gear by

means of locking screws.
Tightening torque (M16x1,5/12,9) ........ MA = 390 Nm
Figure 136
3 / 37
Division
Adjust Backlash – Crown gear set = 0,27 ... 0,33 mm,

Bearing rolling moment - Differential bearing
T = 3.0 ... 4.0 Nm
and
Bracket dimension = 358 –0,1 mm (Fig. 137 and 138):
Determine the backlash by alternately setting of both adjusting

nuts (Fig. 137).
Setting of the adjusting nuts must be made without the

application of force! Differential bearing is not yet allowed to
be preloaded, however, has to be absolutely backlash-free! In
Figure 137 order to ensure this, rotate the differential several times
during the setting procedure!
Determine the bearing rolling moment and the bracket

dimension by further tightening of both adjusting nuts.
As per experience the required bearing rolling moment

as well as the bracket dimension are obtained at further
tightening both adjusting nuts by 1 – 2 notches each.
Check bracket dimension (Fig. 138) once again and correct it, if
required!
(S) Magnetic stand 5870 200 055

(S) Dial indicator 5870 200 057
Figure 138 (S) Micrometer 5870 340 510
Check contact pattern – Crown gear set (Figure 139 a. 140):
Ink mark some driving and coasting flanks.
Figure 139
Roll the crown gear over the input pinion in both directions
several times.
Compare the contact pattern obtained with the contact pattern
examples Page 0.6 and 07.
If the contact pattern differs, there has been a measuring

error at determination of the shim (Page 3/14 ... 3/15) which
is mandatory to be corrected!
Figure 140
3 / 38
Division
Fasten adjusting nut by means of slotted pin (arrow).
Figure 141
Install stud bolts (4x, see arrows).
Wet screw-in thread (length 20 mm) with

Loctite (Type No. 262)!
Tightening torque (M16) .................... MA = 55 Nm
Figure 142
Wet mounting face with sealing compound (Loctite, Type

No. 574)!
Figure 143
Locate the axle insert by means of lifting tackle on the axle and
fasten it by means of locking screws and hexagon screws.
Tightening torque (locking screws) ............... MA = 375 Nm

Tightening torque (hexagon nuts) ................. MA = 280 Nm
Figure 144
3 / 39
Division

3.2.4 Flange shaft
Install shaft seal with the sealing lip showing to the oil chamber.
By use of the specified driver (S) the exact installation posi-

tion will be obtained!
Depending on the version varying shaft seals can be used:

Outer diameter rubber-coated – wet with spirit;
Outer diameter metallic – wet with sealing compound
Figure 145 (S) Driver 5870 048 051
Assemble flange (arrow).

Heat ball bearing and locate it on the collar of the flange shaft.
Figure 146
By means of adjusting shim (optional) and retaining ring

adjust ball bearing to be backlash-free.
(S) Set of pliers 5870 900 016
Figure 147
Heat housing bore.
(S) Hot-air blower 230V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 148
3 / 40
Division

Type No. 574).
Figure 149
Install preassembled flange shaft and fasten it by means of

cap screws.
Then install both plug shafts, also see chapter 1!

Left and right plug shafts are differently long !

Figure 150 Prior to initial operation of the axle pay attention to lubri-
cation and maintenance instructions, see Page 0/9 to 0/11 !
3 / 41
Division

Type No. 574).
Figure 149
Install preassembled flange shaft and fasten it by means of

cap screws.
Then install both plug shafts, also see chapter 1!

Left and right plug shafts are differently long !

Figure 150 Prior to initial operation of the axle pay attention to lubri-
cation and maintenance instructions, see Page 0/9 to 0/11 !
3 / 41

ZF - Axle Ap-17: Differential Carrier Type: Lkst-2 and LKZ - 7

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: 5871 209 002 E

INSTRUCTIONS CONCERNING THE REPAIR MANUAL

Abt.: ASTDM / Section : ASTDM

1. Constantly trained personnel

2. Prescribed installations, e.g. Special Tools

3. Genuine ZF-Spare Parts according to the latest phase of development

Structure of the Repair Manual

Important information on industrial safety

Serves as reference to special working procedures, methods,

CAUTION Is used, if a deviating and improper working procedure can damage

Is used, if lacking care can lead to personal injury or danger to

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Density lineaire en kg/m; Density superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2,205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7,233 lbf x ft ( pound force foot)

1,356 Nm ( 0,138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5,560 lb / in ( pound per inch )

0° C ( Celsius ) = + 32° F ( Fahrenheit )

TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG

EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE

EXEMPLES POUR LA DENTURE GLEASON

Ideales Tragbild d.h. die Ritzeldistanz stimmt

Ideal tooth-contact pattern i.e. pinion distance is correct

L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte

Bild / Figure 1/3/5 Bild / Figure 1

Coast side (concave)

Côté poussé (concave)

Bild / Figure 2/4/6 Bild / Figure 2

Drive side (convex)

Côté entraîné (convexe)

Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden

Pinion distance must be increased Pinion distance must be decreased

Bild / Figure 3 Bild / Figure 5

Bild / Figure 4 Bild / Figure 6

TORQUE LIMITS FOR SCREWS (IN Nm) TO ZF-STANDARDS 148

Metric ISO-Standard thread DIN 13, Page 13

Metric ISO-Fine thread DIN 13, Page 13

1. OIL QUALITY: To ZF List of Lubricants TE-ML 05

2.1 Oil drain - Output (Figure 1)

Loosen screw plug and cap screw (arrows) and

2.2 Oil drain – Axle insert LKST-2 (Figure 2):

Loosen screw plugs (arrows) and drain oil from the

2.3 Oil drain – Axle insert LKZ-7 (Figure 3):

Loosen screw plugs (arrows) and drain oil from axle

2.3 Oil filling - Output (Figure 4):

Install cap screw (arrow).

Tightening torque (cap screw) ..... MA = 280 Nm

Fill up oil according to oil level marking.

Tightening torque ................ MA = 150 Nm

2.4 Oil filling – Axle insert LKST-2 (Figure 5 and 6):

Provide both screw plugs (arrows 1 and 2) with new

Tightening torque (M24x1,5) .............. MA = 70 Nm 3

Tightening torque (M42x1,5) ....... MA = 150 Nm Fig. 5

Tightening torque (M42x1,5) ............ MA = 150 Nm

2.5 Oil filling – Axle insert LKZ-7 (Figure 6 a. 7)

3. OIL CHANGE INTERVALS:

1. Oil change after 500 operating hours.

4. OIL LEVEL CHECK: