Spicer Axle 123

Service Manual
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Axle 123
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ASM-0007E
March 2013
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CONTENTS
INTRODUCTION ................................................................................................................................ 5
SPECIFICATIONS .............................................................................................................................. 6
DEFINITION OF VIEWPOINTS .................................................................................................................................... 6
DATA PLATE .............................................................................................................................................................. 6
CONVERSION TABLES ................................................................................................................................................... 7
TORQUE SPECIFICATIONS ............................................................................................................................................ 8
COARSE PITCH ......................................................................................................................................................... 8
FINE PITCH ................................................................................................................................................................ 8
WHEEL NUT TIGHTENING TORQUES ...................................................................................................................... 9
MAINTENANCE ................................................................................................................................................................ 10
MAINTENANCE POINTS ............................................................................................................................................ 10
MAINTENANCE INTERVALS ...................................................................................................................................... 11
ADJUSTMENT AND CHECKS .................................................................................................................................... 11
LUBRICANT & SEALANT SPECIFICATIONS ............................................................................................................. 12
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SAFETY PRECAUTIONS ................................................................................................................... 13
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BRAKE WEAR CHECK PROCEDURE .............................................................................................. 15
OLD VERSION ................................................................................................................................................................. 15
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NEW VERSION ................................................................................................................................................................. 16
SPECIAL TOOLS .............................................................................................................................................................. 17
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T1 ............................................................................................................................................................................... 17
SERVICE BRAKE ............................................................................................................................... 19
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EXPLODED VIEW ............................................................................................................................................................. 19
DISASSEMBLY ................................................................................................................................................................ 20
ASSEMBLY ...................................................................................................................................................................... 22
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PLANETARY REDUCTION ................................................................................................................ 25
EXPLODED VIEW ............................................................................................................................................................. 25
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DISASSEMBLY ................................................................................................................................................................ 26
ASSEMBLY ...................................................................................................................................................................... 30
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SPECIAL TOOLS .............................................................................................................................................................. 33

T1 ............................................................................................................................................................................... 33
T2 ............................................................................................................................................................................... 34
T3 ............................................................................................................................................................................... 35
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DIFFERENTIAL UNIT ........................................................................................................................ 37

EXPLODED VIEW ............................................................................................................................................................. 37
DISASSEMBLY ................................................................................................................................................................ 38
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ASSEMBLY ...................................................................................................................................................................... 42
SPECIAL TOOLS .............................................................................................................................................................. 48
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T1 ............................................................................................................................................................................... 48
BEVEL PINION ................................................................................................................................... 49
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EXPLODED VIEW ............................................................................................................................................................. 49

DISASSEMBLY ................................................................................................................................................................ 50
ASSEMBLY ...................................................................................................................................................................... 53
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SPECIAL TOOLS .............................................................................................................................................................. 58

T1 ............................................................................................................................................................................... 58
T2 ............................................................................................................................................................................... 59
T3 ............................................................................................................................................................................... 59
T4 ............................................................................................................................................................................... 60
T5 ............................................................................................................................................................................... 61
ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 3

FLANGED BEVEL PINION ................................................................................................................ 63
EXPLODED VIEW ............................................................................................................................................................. 63
DISASSEMBLY ................................................................................................................................................................ 64
ASSEMBLY ...................................................................................................................................................................... 66
SPECIAL TOOLS .............................................................................................................................................................. 71
T1 ............................................................................................................................................................................... 71
T2 ............................................................................................................................................................................... 72
T3 ............................................................................................................................................................................... 72
SWINGING SUPPORT ....................................................................................................................... 73
EXPLODED VIEW ............................................................................................................................................................. 73
DISASSEMBLY ................................................................................................................................................................ 74
ASSEMBLY ...................................................................................................................................................................... 75
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SERVICE BRAKE AND NEGATIVE PARKING BRAKE .................................................................... 77
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EXPLODED VIEW ............................................................................................................................................................. 77
RELEASE ......................................................................................................................................................................... 78
ADJUSTMENT ................................................................................................................................................................. 78
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DISASSEMBLY ................................................................................................................................................................ 79
ASSEMBLY ...................................................................................................................................................................... 82
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4 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on
efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have
been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is
necessary to assemble only individual components, when partial repair work is needed. The manual provides a
quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the ope-
rations, allows accurate work to be performed.All the information needed for correct disassembly, checks and as-
sembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the
manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is pre-
sumed that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use pro-
per equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and
specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly
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clean the unit, removing any encrusted or accumulated grease.
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INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate
products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly
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check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (o-rings,
oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time
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a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge.
In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other
one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained.
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CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification
is indicated as follows:
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 = up to the part number
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 = from the part number on
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When no classification is given, disassembly and assembly operations are the same for all versions.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair
work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or
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directly from the Service Centers or Authorized Distributors of SPICER.

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SPECIFICATIONS
DEFINITION OF VIEWPOINTS
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DATA PLATE
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MFG. BY CLARK-HURTH COMPONENTS S.P.A.
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38062 Arco (Trento)

MADE IN ITALY
1 - Type and model unit - modification index

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2 - Serial number
3 - Lubricant
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CONVERSION TABLES
CONVERSION TABLES
UNITS OF PRESSURE
1 ATM=1 BAR=105 PA=14.4 PSI
UNIT OF WEIGHT
N daN kN kg lbs
1N 1 0,1 0,001 0,102 0,225

1daN 10 1 0,01 1,02 2,25
1kN 1000 100 1 102 225
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1kg 9,81 0,981 0,00981 1 2,205
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UNITS OF TORQUE
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N·m daN·m kN·m kg·m lb·in
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1N·m 1 0,1 0,001 0,102 8,854
1daN·m 10 1 0,01 1,02 88,54
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1kN·m 1000 100 1 102 8854
1kg·m 9,81 0,981 0,00981 1 86,8
1 lb·in 0,1129 0,01129

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0,0001129 0,01152 1
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TORQUE SPECIFICATIONS
COARSE PITCH
SIZE OF BOLT TYPE OF BOLT

8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m
M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m
M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m
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M14 x 2 mm 129 – 143 N·m 143 – 158 N·m 182 – 202 N·m 200 – 221 N·m 221 – 244 N·m 238 – 263 N·m
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M27 x 3 mm 998 – 1103 N·m 1088 – 1202 N·m 1411 – 1559 N·m
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FINE PITCH
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M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m
M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m
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WHEEL NUT TIGHTENING TORQUES
Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material.
RECOMMENDED WHEEL NUTS TORQUE
CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY
ST 37 **ST 52
M18 x 1,5 mm 330 N·m 460 N·m

WHEEL NUTS WITH
INTEGRATE M20 x 1,5 mm 490 N·m 630 N·m
SPHERICAL COLLAR
M22 x 1,5 mm 630 N·m 740 N·m
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FLAT COLLAR WHEEL M18 x 1,5 mm 270 N·m 360 N·m
NUTS WITH SEPARATE
M20 x 1,5 mm 360 N·m 450 N·m
SPHERICAL LOCK
WASHER
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M22 x 1,5 mm 460 N·m 550 N·m
M18 x 1,5 mm 260 N·m 360 N·m

WHEEL NUTS WITH IN-
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TEGRATE SEAT M20 x 1,5 mm 350 N·m 500 N·m
CAPTIVE WASHER
M22 x 1,5 mm 450 N·m 650 N·m
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**RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS. IT IS THE OPTIMUM MA-
TERIAL FOR TIGHTENING THE RIM TO THE HUB.
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NOTE:
The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant).
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NOTE:
The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of
the rim material.
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THE DANA OFFICIAL TIGHTENING TORQUE TABLE, THAT IS INCLUDED IN EACH SERVICE MANUAL, SHOWS THE TORQUE FIGURE
RELATED TO THE BOLT CHARACTERISTIC ONLY.
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DANA OFFICIAL TIGHTENING TORQUE TABLE

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NUT MATERIAL QUALITY 8.8 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE
M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m

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M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m
M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m

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*THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY
(DANA AXLES ARE 10.9 ONLY).

MAINTENANCE
MAINTENANCE
MAINTENANCE POINTS
4 4
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1 3
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2 4 2 4
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1 3
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1 - Oil filling plug

2 - Oil draining plug
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3 - Check level plug

4 - Check brake disc wear
Minimum thickness between counter discs is 5.2 mm.
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NOTE:
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For details see BRAKE WEAR CHECK PROCEDURE p. 15

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MAINTENANCE
MAINTENANCE INTERVALS
OPERATION FREQUENCY LUBRICANTS
Differential Monthly SAE85W90 (API GL4 - MIL L-2105)

Check levels
Planetary reduction Every 200 hours With additives for oil-bath brakes
Differential Every 800 hrs * SAE85W90 (API GL5 - MIL 2105-B)

With additives for oil-bath brakes, for units
Oil change Planetary reduction Every 1000 hrs * presenting hypoid crown wheel and pinion
L.S. Differential Every 700 hrs */** and/or self-locking differential gear
If working in severe duty conditions half intervals should be used
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* Initially after 100 working hours
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** When it starts sounding noisy
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OPERATION MEMBER CONDITIONS FREQUENCY LUBRICANTS
Normal work Monthly
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Greasing Articulations NLGI 3 EP
Severe duty Weekly
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ADJUSTMENT AND CHECKS
UNIT OPERATION FREQUENCY

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Negative brake Adjustment Every 1000 hours*

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Only for mineral oil use e.g. ATF Dexron II. Make
Service brake Adjustment Every 500 hours sure that master cylinder seals are suitable for mine-
ral oil.
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Wheel nuts Tightening Every 200 hours**

** Initially after 10 working hours
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MAINTENANCE
LUBRICANT & SEALANT SPECIFICATIONS

1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate repla-
cement with similar products marketed by different brand names with different trade marks.
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Be-
fore using it, completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
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Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubri-
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cant by using the specific activator.
To remove parts, it may be necessary to heat them at 80° C approximately.
LOCTITE 275
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Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for
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pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum dia-
metrical clearance of 0.25 mm.
LOCTITE 510
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Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal
clearances between flanges up to 0.2 mm. ic
LOCTITE 577
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it,
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remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so
heating may be necessary for larger diameters.
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LOCTITE 638
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with clearance ranging between 0.1 and 0.25 mm.
LOCTITE 648
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Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with radial clearance below 0.1 mm.
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AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS)

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Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter
of sealing rings for rotating shafts with outer metal reinforcement.
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SILICONE
Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and phy-
sical elements. Polymerises with non-corrosive dampness.
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TECNO LUBE/101 (SILICONE-BASED GREASE)

Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
MOLIKOTE (DOW CORNING)
Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sti-
cking and oxidation of parts that are not lubricated on a regular basis.
(LITHIUM-BASED) GREASE
Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.

SAFETY PRECAUTIONS
1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po-
sitioned and that the machine is locked lengthways.
4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the igni-
tion key from the machine.
5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure
that all torque wrenches have been checked and calibrated.
6 - Always wear gloves and non-slip rubber shoes when performing repair work.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste
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and dispose of them according to the relative law provisions obtaining in the country where the axles are being
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overhauled.
9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol,
xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment
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friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some
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of the diagrams.
11 - After repair work has been completed, accurately touch up any coated part that may have been damaged.
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12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.
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MAINTENANCE
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BRAKE WEAR CHECK PROCEDURE
OLD VERSION
CAUTION
Perform all operations on both arms.
35 - 50 N·m
FIGURE 4: Fill with oil.
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Install the oil drain plug.
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Torque wrench setting for screws: 35 - 50 N·m.
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FIGURE 1: Remove the oil drain plug and discharge oil.
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T1
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FIGURE 2: Apply the parking brake (or have someone hold

the service brake) and with either brake applied, check the di-
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stance between discs using tool T1 (See drawing T1 p. 17).

Minimum distance: 5,2 mm
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CAUTION
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Replace the braking disks and the intermediate disks on

both sides if necessary. See SERVICE BRAKE p. 19.
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FIGURE 3: Checking brake distance with the T1 go / no-go

gauge.

NEW VERSION
CAUTION
35 - 50 N·m
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FIGURE 4: Install the inspection plug.
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FIGURE 1: Remove the inspection plug.
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T1
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CAUTION
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both sides if necessary. See SERVICE BRAKE p. 19.

gauge.

SPECIAL TOOLS
SPECIAL TOOLS
T1
5.2
°
45
1
25
32
32
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160
110
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32
32
25
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°
45
10
5.4
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SPECIAL TOOLS
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SERVICE BRAKE
EXPLODED VIEW
1
4
7
8
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10
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12
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14
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DISASSEMBLY
DISASSEMBLY
Differential side Arm side
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FIGURE 4: Write down the flange (4) position.
FIGURE 1: Sling the arm to be removed and connect it to a
hoist. Loosen and remove screws.
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3
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FIGURE 5: Remove braking discs (2, 3), noting down direc-

tion of assembly.
FIGURE 2: Write down the order of assembly and remove the
NOTE:
counterwasher (1).
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If disks are not to be replaced, avoid changing their posi-

tion.
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Down Side
FIGURE 3: Write down the counterwasher (1) position.
FIGURE 6: Remove the flange (4) complete with the discs.

DISASSEMBLY
5
2
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FIGURE 7: Remove braking discs (2, 3), noting down direc- FIGURE 9: Remove the adjusting screws (5)
tion of assembly.
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NOTE:
If disks are not being replaced, avoid changing their posi-
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tion.
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adjusting screws
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FIGURE 8: Remove the reversal springs (7)

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FIGURE 10: Slowly introduce low-pressure compressed air

through the connection member for the service brake (P1), in
order to extract the piston (9).
reversal springs CAUTION

Hold the piston (9) back, as it may be suddenly ejected and
damaged.

ASSEMBLY
ASSEMBLY
Loctite 242
5 - 7 N·m
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FIGURE 14: Fit the reversal springs (7) on the piston (9). Apply
LOCTITE 242 to the thread of the adjustment screw.
FIGURE 11: Insert the stroke automatic regulation springs (6); Tighten with torque wrench setting of 5 - 7 N·m
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place them in line with the piston (9).
Loctite 270
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11 10 - 15 N·m
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12 10
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FIGURE 12: Fit o-ring (11, 12) and back-up ring (10, 13) onto
the piston (11). FIGURE 15: Fit the adjusting screws (5).
Lubricate the piston and the o-rings and install the unit into Apply Loctite 270 to the thread.
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the arm (14). Torque wrench setting: 5 - 7 N·m.

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reversal springs
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14 adjusting screws
FIGURE 13: Using a plastic hammer, install the piston (9) into
the arm (14).
NOTE:
Lightly hammer all around the edge in an alternate se-
quence.

ASSEMBLY
ﬁrst disc
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FIGURE 16: Insert the brake discs in the correct sequence.
FIGURE 19: Insert the intermediate disk (1).
NOTE:
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The first brake disc (2) to be inserted must be of metal
material.
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second disc
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FIGURE 20: Check condition and position of the cylinder's o-

ring.
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FIGURE 17: The second brake disc (3) to be inserted must be

of friction material.
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NOTE:
The last brake disc to be inserted must be of friction ma-
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terial.
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Up side
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Loctite 242
200 - 221 N·m
FIGURE 21: Cross tighten the nuts in two stages.
Torque wrench setting: 200 - 221 N·m
4
FIGURE 18: Install the flange (4) on the arm.

ASSEMBLY
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PLANETARY REDUCTION
EXPLODED VIEW
2
3
21
1 4
5
6
20
19 9
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18 17 7
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16
8 10
14
11
15
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24
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12
26
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23
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25 28
27 30
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DISASSEMBLY
DISASSEMBLY
29
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FIGURE 4: Remove the cover (29).
30
FIGURE 1: Remove oil level plug (30) and the oil.
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31
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FIGURE 5: Remove the axle half shaft (4).
FIGURE 2: Remove the planetary cover (29) capscrews (31).

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29
FIGURE 6: Remove the planetary gear (14) snap rings (16).
FIGURE 3: Using two screwdrivers or two levers inserted in

the slots provided, pry the planetary cover (29) away from the
wheel hub (10).

DISASSEMBLY
14
22
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FIGURE 7: Remove the planetary gears (14). FIGURE 10: Inspect the o-ring (22).
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27
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Down
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FIGURE 8: Write down direction of assembly of planetary ge- FIGURE 11: Loosen the nuts (27) and remove them.
ars.
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28 FIGURE 12: Remove the safety flange (26).

FIGURE 9: Check the wear of the shim washer (28).

DISASSEMBLY
23 13
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FIGURE 13: Using an extractor and applying a counter pres- FIGURE 16: Extract the external bearing (13).
sure to the screws (25), disengage the crown wheel (23) from
the hub (10).
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10
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FIGURE 17: Using an extractor and applying a counter pres-

23 sure to the screws, disengage the hub (10).
FIGURE 14: Remove the crown (23).
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10 10
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8
13
FIGURE 18: Remove the internal bearing (8) and the hub (10).
FIGURE 15: With the help of a plastic hammer, shift the hub
(10) and the external bearing (13).

DISASSEMBLY
10
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FIGURE 22: Remove the external thrust blocks of bearings,
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FIGURE 19: Remove the seal ring (7) from the hub (10). using a pin driver.
NOTE: NOTE:
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Write down direction of assembly. Hammer in an alternate sequence to prevent clamping
and deformation of the thrust blocks.
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CAUTION
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The seal ring may not be reused.
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10
FIGURE 23: Using an extractor, remove seal ring (5) and gui-
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de ring (6).
NOTE:
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FIGURE 20: Remove the internal bearing (8) and sealing ring (7).
Write down the direction of assembly of snap ring.
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Oil Side
FIGURE 21: Remove the external thrust blocks of bearings, Sealing Ring Guide Ring
using a pin driver.
NOTE:
Hammer in an alternate sequence to prevent clamping
and deformation of the thrust blocks.

ASSEMBLY
ASSEMBLY
T2
8
10
T1
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FIGURE 27: Lubricate the seats of the bearings and position
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the hub (10) on tool T2 (See drawing T2 p. 34); position the
thrust block of the internal bearing (8).
FIGURE 24: Lubricate and fit the seal ring (5) and guide ring(6)
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onto tool T1 (See drawing T1 p. 33); install the rings into the NOTE:
arm.
Check that the thrust block is correctly oriented.
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Oil Side
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Sealing Ring Guide Ring

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FIGURE 25: Pay particular attention to the direction of as- FIGURE 28: Fit the bearing (8) and seal ring (7) into the inter-
sembly of the rings. nal thrust block.
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T3
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13
T2
FIGURE 26: Position the lower part of tool T2 (See drawing FIGURE 29: Using special tool T3 (See drawing T3 p. 35) ap-
T2 p. 34) and the thrust block of the external bearing (13). ply a repositionable jointing compound for seals to the outer
surface of the sealing ring (7). Position the sealing ring (7) in
the hub (10).
NOTE:
Check that the ring (7) is correctly oriented.

ASSEMBLY
13
s
ne
FIGURE 30: Install the wheel hub. FIGURE 33: Fit the complete crown flange (23).
NOTE:
rli
In order to fasten the flange (23), use a plastic hammer
and alternately hammer on several equidistant points.
Ai
Tecno Lube/101
an
26
ic
er
Am
FIGURE 31: Install the external bearing (13).
NOTE:
Move the bearing to the limit stop by hammering lightly all
of
around the edge. FIGURE 34: Install the security flange (26).
Using Tecno Lube /101, grease the surface of the safety flan-
ge (26) that touches the crown wheel.
ty
23
Loctite 242
er
330 - 385 N·m

27
op
Pr
FIGURE 32: Install the crown wheel (23).
FIGURE 35: Coat the nuts (27) with Loctite 242 and tighten in
two stages, using the criss-cross method.
Initial torque wrench setting: 330 N·m
Final torque wrench setting: 385 N·m

ASSEMBLY
12
Down
s
ne
FIGURE 36: Check the condition and position of the o-ring FIGURE 39: Inspectthe orientation.
(12).
rli
Ai
an
28 ic
er
Am
FIGURE 40: Fit the planetary carrier cover onto the hub.
FIGURE 37: Fit shim washer (28) into spider cover (29).
CAUTION
of
Check that the o-ring is in good condition and in position.

16
ty
35 - 50 N·m
er
op
14
Pr
FIGURE 38: Insert the planetary gears (14) into the cover (29).
Lock gears (14) into position by installing the snap rings. 31
FIGURE 41: Lock the planetary carrier cover by tightening the

screws. Torque wrench setting for screws: 35 - 50 N·m.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 17710
ø80
ø62,5
M16
s
ne
rli
Ai
an
105
ic
90
85
er
Am
35
25
of
ty
ø35
er
ø45
op
ø61,5
Pr

SPECIAL TOOLS
T2
P/N: 3265
Ø184
Ø4 0 Ø3 5
12. 5
25
45
32
0
R1
s
20°
176
ne
131
rli
5x15 °
Ai
32
-- 0. 1
Ø5 0
an
-- 0. 3
Ø178 27. 5
20°
Ø4 5
ic
0. 8
0. 8
er
0. 8
Am 20
60
5x15 °
47.631
126
166
0. 8
of
Ø50 H7
141
R3
Ø60 H7-p 6
ty
er
op
0. 8
Ø165
0. 8
Ø184
± 0.03
Pr
Ø200

SPECIAL TOOLS
T3
P/N:
Ø180
Ø40
30
s
140
ne
90
rli
Ai
0
R1
R3
an
15
10
46
7-0.5
0
28
ic
14
6.5
er
Ø140
Ø154 +-- 0.2
0.1
Ø178
Am
Ø189
Ø205
of
ty
er
op
Pr

SPECIAL TOOLS
s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

DIFFERENTIAL UNIT
EXPLODED VIEW
1 2
3 4
7
8 9
5 10
19
39 6 17 20
s
18
38
ne
22
12
40 24
13
rli
14
28 29 15 21
Ai
30
41
23 27
37
an
25 26
31
ic
32
er
33
Am
34
36
35
of
ty
er
op
Pr

DISASSEMBLY
DISASSEMBLY
2 26
T1
s
ne
FIGURE 4: If removal or adjustment is necessary, use special
tool T1 (See drawing T1 p. 48) and mark the position of the
FIGURE 1: Sling the arm to be removed and connect it to a ring nuts (2) and (26).
rli
hoist. Loosen and remove screws and nuts.
Ai
an
ic
er
Am
FIGURE 5: Loosen the stud bolts (35, 41) and remove two of
FIGURE 2: If removal or adjustment is necessary, remove the them.
of
screw (27).
ty
er
op
Pr
38 33
FIGURE 6: Disjoin the cover (38, 33) crown side.

FIGURE 3: If removal or adjustment is necessary, uniformly
heat the ring nuts up to a temperature of 176°F (80C°).

DISASSEMBLY
29
s
ne
FIGURE 7: Remove the cover and studs. FIGURE 10: Remove the cap (29).
rli
3 25
Ai
an37 36
ic
er
33 38
Am
FIGURE 8: Extract the complete differential unit. FIGURE 11: If the bearings need replacing, extract the exter-
nal thrust blocks of the bearings (3) and (25) from middle co-
ver (33, 38).
of
NOTE:
30 Accurately check the o-ring (37, 36).
ty
er
op
Pr
3
FIGURE 9: Remove the snap ring (30).
FIGURE 12: If the bearing needs replacing, extract the bea-

ring (3).

DISASSEMBLY
24
25
23
s
ne
FIGURE 13: If the bearing need replacing, extract the bearing FIGURE 16: Remove the screws (24) jointing the differential
(25) from the differential carrier (23). unit half box.
rli
Ai
an
4
23
ic
er
5
Am
FIGURE 14: Remove the capscrews (4) of the crown (6). FIGURE 17: Using a plastic hammer, take the half box (23, 5)
apart.
of
NOTE:
42
Write down the coupling marks.
ty
23
er
op
6
Pr
FIGURE 15: Remove the spacer (42) and the crown (6).
FIGURE 18: Remove the upper half box (23).

DISASSEMBLY
22
8
21
s
ne
FIGURE 19: Remove shoulder (22) and first planetary gear FIGURE 22: Remove the 2nd planetary gear (8) and shoulder
(21). ring (7).
rli
15 19 18 23 5
Ai
an
14 20 P
ic
SR
Sw
er
Sh
Am
S
FIGURE 20: Remove shafts (18), complete with planetary ge- FIGURE 23: The differential unit.
ars (15, 19) and spherical shoulder washers (14, 20).
Sh = Shafts (18)(17)
of
9 13 17 SW = spherical shoulder washers (9)(13)(14)(20)

P = planetary gears (8)(21)
ty
SR = shoulder ring (22)(7)

er
10 12 S = planetary gears (10)(12)(15)(19)

23 = upper half box
op
5 = half box crown side

Pr
FIGURE 21: Remove shafts (17), complete with planetary ge-


ASSEMBLY
ASSEMBLY
22
8
21
s
ne
5 FIGURE 27: Install the planetary gear (21) and shoulder ring
(22).
FIGURE 24: Install the shoulder ring (7) and planetary gear (8)
rli
into the halfbox (5).
23
Ai
9 13 17
10 12
an
ic
er
Am
FIGURE 28: Mount the locking half-box (5) onto the half-box
(23)
FIGURE 25: Install the planetary gears (10, 12) and spherical
of
shoulder washers (9, 13) onto the shafts (17).

Install the planetary set. Loctite 270
ty
15 19 18
er
24
op
14 20
Pr
FIGURE 29: Lock the half box with screws (24) coated with
Loctite 270.
shoulder washers (14, 20) onto the shafts (18). CAUTION
Install the planetary set.
1 -The match marks on the two half-boxes must correspond.
2 - Use only new screws.

ASSEMBLY
80 N·m 150 N·m
24
s
ne
FIGURE 30: Fit the complete differential unit in a vice and FIGURE 33: Lock the ring gear (6) by tightening the screws (4)
tighten the screws (24) holding the two half boxes together to to a torque of 150 N·m.
a torque of 80 N·m.
rli
CAUTION
Ai
CAUTION
Tighten screws using the criss-cross method.
42
an 100°
ic
er
3
Am
6
of
FIGURE 34: INSTALLATION OF THE DIFFERENTIAL UNIT

FIGURE 31: Install the spacer (4) and the crown (6).
Position the differential unit under a press and, using a driver
ty
with an adequate diameter, install the first bearing (3).

Loctite 270
er
op
Pr
FIGURE 32: Mount the ring gear (6) and fasten it to the diffe-
rential box with screws (4).
CAUTION
Use only new screws.

ASSEMBLY
Loctite 242
35 140 N·m
25
33
s
ne
FIGURE 35: Turn the unit upside down and install the second FIGURE 38: Fit the intermediate cover (33) on opposite side of
bearing (25). ring gears. Lock cover with screws (35) coated with Loctite
242. Tighten screws to a torque of 140 N·m.
rli
CAUTION
Ai
Pay particular attention; position a shim with adequate dia-
meter in order to engage the internal ring of bearing without
engaging the cage.
an
ic
er
Am
FIGURE 39: Position the differential unit in the central body

with the help of a bar and fit the middle cover.
of
ty
C
FIGURE 36: Only if bearings are replaced
Insert the thrust blocks of the bearings into the intermediate
er
covers.
op
36 37
Pr
38
FIGURE 40: Tighten the two safety screws “C” into the main
body (28) and install the intermediate cover (38).
FIGURE 37: Thoroughly check the state of the o-ring (36, 37).

ASSEMBLY
Loctite 242
140 N·m
TM
s
ne
FIGURE 41: Tighten screws to a torque of 140 N·m. FIGURE 44: Apply torque meter TM to pinion nut and check
that torque will increase by 20 - 40 N·cm as a result of diffe-
rential bearing preload.
rli
1/4 turn Example: pinion torque: 120 - 130 N·cm Pinion + differential
torque: 140 - 170 N·cm.
Ai
an
ic
A
er
T1 2
Am
FIGURE 42: Only if ring nuts have been removed. Tighten the
ring nut (2) on ring gear side until clearances between pinion
and ring gear are zeroed. Then, loosen by about 1/4 turn.
of
FIGURE 45: Introduce a dial indicator “A” with long tracer

through the hole provided for the cap. Position the tracer on
the side of a tooth of the ring gear, approximately 5 mm from
ty
the outer rim; preload by about 1 mm and zero the gauge.

er
Gap = 0,25 - 0,33 mm

op
Pr
T1 26
FIGURE 43: Only if ring nuts have been removed.

Preload bearings with ring nut (26) on non-ring gear side in or-
der to increase the torque of the pinion.
CAUTION FIGURE 46: As you hold the pinion in position, move the ring
gear manually in both directions to check clearance between
In the case of used bearings, check thrust torque; in the pinion and ring gear. Standard clearance: 0,25 - 0,33 mm
case of new bearings, check continuous torque.

ASSEMBLY
Loctite 242
24 - 26 N·m
2 26
1 27
s
ne
FIGURE 47: If torque and/or pinion-ring gear clearance is not FIGURE 49: Engage screw (27) in the slot next to the holes
within tolerance values and the ring nuts have not been remo- provided for the check screws.
ved, mark the position of the ring nuts (2, 26) and remove the Coat screws (27) with Loctite 242 and tighten to a torque of
rli
safety plates (1, 27). 24 - 26 N·m.
Ai
an
ic
er
Am
T1
FIGURE 48: Adjusting clearance between pinion and ring ge- FIGURE 50: Fit the top plug after applying repositionable
of
ar. To INCREASE: loosen the ring nut on ring gear side and jointing compound for seals to the rims. Install the snap ring.
tighten the ring nut on non-ring gear side by the same mea-
sure.
ty
To DECREASE: perform the same operations inversely. To

rotate ring nuts, use special wrench T1 (See drawing T1
p. 48).
er
op
Pr
FIGURE 51: Install the complete arm.

ASSEMBLY
283 - 312 N·m
s
ne
FIGURE 52: Torque wrench setting: 283 - 312 N·m.
NOTE:
rli
Tighten using the criss-cross method.
Ai
an
ic
er
Am
of
ty
er
op
Pr

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2379
¯ 166
10 x15
¯ 40.5 ---- 0.1
0.2
0.8
¯ 15H7-n6
s
100
ne
¯ 14
2 x15
rli
0.8
24
17
20
Ai 238
0
R1 ¯ 25
an
¯ 10
¯ 35
123
ic
125
er
33
36
Am
¯ 37H7-n6
of
¯ 47
ty
¯ 143 0.1
er
R 30
25
op
Pr

BEVEL PINION
EXPLODED VIEW
3 6
s
2
14
ne
15
17
7
1
rli
8
13
Ai
9
11
10
an 16
ic
er
Am
of
12
ty
er
op
Pr

DISASSEMBLY
DISASSEMBLY
2
1
10
11 10
s
ne
FIGURE 1: Remove both axle arms.
rli
Ai
an
ic
10
er
FIGURE 4: Remove the flange (10) complete with guard (2).
1 10
Am
FIGURE 2: If disassembly is difficult, heat the check nut (1) of

the flange (10) at 176°F (80C°).
of
NOTE:
Heating is meant to loosen the setting of Loctite on the
ty
nut (1).
er
op
9
Pr
FIGURE 5: Remove the sealing ring (9).

T1
FIGURE 3: Position tool T1 (See drawing T1 p. 58), to avoid

pinion rotation.
Loosen and remove the nut (1); also remove the o-ring (11).

DISASSEMBLY
T2
s
ne
FIGURE 6: Apply blocks T2 (See drawing T2 p. 59) and, with FIGURE 9: Remove the thrust block of the external bearing
the help of a puller, extract the pinion (5) complete with the in- (3).
ternal bearing (6), the spacer (8) and calibrated spacer (4, 7).
rli
NOTE:
Ai
The thrust blocks of the bearings remain in the central
body (12).
17
an
ic
7
er
Am
FIGURE 10: Insert a drift in the appropriate holes.

of
FIGURE 7: Remove spacer (17) and calibrated spacer (7).

ty
er
op
5
4
Pr
6
6
FIGURE 11: Remove the thrust block of the internal bearing
(6) as well as the shim washers (4).
FIGURE 8: Using a puller and a press, remove the inner bea-

ring (5) from the pinion (6).

DISASSEMBLY
15
s
ne
rli
Ai
an
ic
er
14
Am
FIGURE 13: Remove the cap (14).

of
ty
er
op
Pr

ASSEMBLY
ASSEMBLY
I = 135
M5
- 0,1 = Y
s
42 mm
ne
FIGURE 16: Check nominal dimension “I” as marked on the
pinion. Add up to or subtract from “I” the variation indicated
FIGURE 14: CALCULATING PINION CENTER DISTANCE as “Y” to obtain the actual center distance “I”.
rli
Using a faceplate, reset a dial indicator “DG” on a calibrated EXAMPLE: I = 135 - 0.1 = 134.9
block (whose known thickness is 42 mm.).
Ai
Preload the gauge by about 3 mm. NOTE:
M5 = Match part number
an
ic
er
Am
D
9
of
FIGURE 15: Bring inner bearing (6), complete with thrust

block, under the dial indicator “DG”. FIGURE 17: Calculate shims "S" for insertion under the thrust
ty
EXAMPLE: 42 +0.5 = 42.5 = “D”. block of the inner bearing using the following formula:
S = 178 - (I+D) where: 178 = fixed dimension;
er
I = actual pinion center distance;

CAUTION D= total bearing thickness;
EXAMPLE: S = 178 - (134.9 + 42.5) = 0.6 mm.
op
Press the thrust block centrally and carry out several mea-
surements by rotating the thrust block.
Pr

ASSEMBLY
T3
12
6
6
4
3 3 T4
s
ne
FIGURE 18: Using special tool T3 (See drawing T3 p. 59), FIGURE 20: CALCULATING PINION BEARINGS ROLLING
partially insert the thrust block of the bearings (3) (6) and TORQUE
shims (4) . Introduce tool T4 (See drawing T4 p. 60) complete with bea-
rli
rings (3) and (6) into the main body (12); tighten by hand until
a rolling torque is definitely obtained.
Ai
an
A
ic DDG
A
er
Am
T4 T4
FIGURE 19: Connect the tension rod to the press and move
the thrust block of bearings (3) (6) into the seats.
of
Disconnect the press and remove the tension rod. FIGURE 21: Introduce the tracer of a depth gauge “DDG” into
either side hole of tool T4 (See drawing T4 p. 60). Reset the
NOTE: gauge with a preload of about 3 mm.
ty
Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
er
op
6
Pr
3
FIGURE 22: Remove the comparator and take out tool and
bearing cone kits from the main body.

ASSEMBLY
NOTE:
Once the bearing has cooled down, lightly lubricate bea-
ring (6) with SAE85W90 oil.
T4
H = A - B = 3,9 mm 6
s
ne
FIGURE 23: Reinstall every part, also introducing a spacer
(17) and thicker calibrated spacer between bearing cones (3)
and (6). Tighten the entire pack by hand.
rli
Introduce depth gauge “DDG” in tool T4 (See drawing T4
p. 60) and measure deviation “H” from the previous reset.
FIGURE 26: Make sure that the bearing (6) is well set.
EXAMPLE: H = A - B = 3,9 mm.
Ai
an
17
ic 7
er
S1 7
Am
FIGURE 24: Deviation “H” must be added to a set value of

of
0.12-0.13 mm (X) to obtain the calibrated spacer “S1” (7) for

FIGURE 27: Refer and keep to the positions marked during
insertion between inner bearing (6) and spacer (8).
disassembly.
Dimension “S1” must be rounded off to the higher 5/100.
ty
EXAMPLE: S1 = H + X = 3,9 + (0.12-0.13) = 4,02 - 4,03 mm.

er
5
op
5
Pr
6 FIGURE 28: Fit the pinion (5), calibrated spacer “S1” (7) and
spacer (8) in the main body (12).
FIGURE 25: Heat the inner bearing (6) to about 212°F (100 C°)
and fit it to the pinion (5).

ASSEMBLY
120 - 180 N·cm
s
ne
FIGURE 29: Heat the external bearing (3) to a temperature of FIGURE 32: Apply onto the pinion (5) the bar-hold and with
about 212°F (100 C°) and fit it on to the pinion (5) to complete the help of a torque meter, check the torque of the pinion (5).
the pack as shown in the figure above. Torque: 120 - 180 N·cm
rli
NOTE:
Ai
Lightly lubricate bearing (3) with SAE85W90 oil. CAUTION
If torque exceeds the maximum value, then the size of cali-
brated spacer “S1” (7) between the bearing (6) and the spa-
an
cer (8) needs to be increased. If torque does not reach the
set value, increase the torque setting of the ring nut (1) in dif-
ferent stages to obtain a maximum value of 800 - 1000 N·m.
ic
If torque does not reach the minimum value, then the size of
er
calibrated spacer “S1” (7) needs to be reduced.
When calculating the increase or decrease in size of calibra-
ted spacer “S1”, bear in mind that a variation of calibrated
Am
spacer (4) of 0.01 mm corresponds to a variation of 60 N·cm

5 in the torque of the pinion (5).
10
of
10
FIGURE 30: Install the flange (10) onto the pinion (5) without
sealing ring.
ty
5
Loctite 242
er
800 - 1000 N·m

op
1
Pr
FIGURE 33: Make positional marks across nut (1) and pinion
(5) tang; then remove nut and flange (10)
T1
FIGURE 31: Apply wrench to the ring nut (1) and bar-hold T1
(See drawing T1 p. 58) to the pinion (5). Lock the wrench T1
(See drawing T1 p. 58) and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 800 -
1000 N·m.

ASSEMBLY
12
9 T5 T1
s
ne
FIGURE 34: Apply Arexons rubber cement to the outer surfa- FIGURE 37: Tighten the nut until the match marks line up.
ce of the new seal ring (9) and fit ring in the main body (12)
using driver T5 (See drawing T5 p. 61).
rli
Ai
2
an
ic
er
Am
FIGURE 35: Fit the safety flange (2).

of
Loctite 242
ty
er
1
op
Pr
10 11
FIGURE 36: Oil seal ring lips and install flange (10).
Mount o-ring (11) and apply Loctite 242 to pinion tang; tighten
nut (1).

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2308
¯ 185 0.2
0.2
120
80
¯ 105
s
ne
rli
¯ 105 0.2
25
125
Ai
10
15
25
an
125
ic
¯ 34.5 --+ 00.2
er
¯ 50
Am
135 0.5
97
73
of
61.5
61.5
85
ty
er
126 12
¯ 32 150
10
op 15
Pr
100
¯ 45

SPECIAL TOOLS
T2
P/N: 2381
90
¯17
25
131
s
20
ne
rli
T3
Ai
P/N: 2377
38
122
an
8
R 10 5
0.8
R2
25
0. 8
21.5
ic
0. 8 19.5
er
¯ 104
¯ 109
¯ 55
¯ 69
¯ 85
¯ 89
¯ 35
¯ 70
¯ 80
R3
0.8
¯ 19.5
Am
M18 x 1.5
R2
0.8
27 25
28
10 85
of
30 3 x 15
0.8
¯ 35
ty
0.8
450 80
¯ 25
¯ 19.5
M18 x 1.5
er
550
op
Pr
Cylinder
Bearing thrust block
Bearing thrust block
Central housing

SPECIAL TOOLS
T4
P/N: 2374
¯ 60
30
¯ 6
1/4"
s
0.8
ne
12
rli
70
Ai
0.8
128
3 x 15
38
an
0.8
ic M16 x 1.5
20
¯ 20
er
-0.2
¯ 50 -0.4
Am
-0.2
¯ 40 -0.4
0.8
¯ 20
3 x 15
M16 x 1.5
of
0.8
40
ty
65
67
er
119
¯ 5
op
163
3 x 15
0.8
-0.02
¯ 50 -0.04
37
0.8
Pr
10
44
0.8
A-A
10
¯ 70

SPECIAL TOOLS
T5
P/N: 2375
¯ 50
30
3x45
110
158
s
195
ne
125
1 x 45
R5
rli
Ai
28.5
R3
6
16.5 +-- 0.0 2
3 x 15
12
0.8
an
¯ 39.5
0.8
¯ 61.5 + 00.1
ic
¯ 85
¯ 98
er
¯ 125
Am
of
ty
er
op
Pr

SPECIAL TOOLS
s
ne
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

FLANGED BEVEL PINION
EXPLODED VIEW
18
16
s
ne
rli
11 12 13
7
Ai
6
5 15 16
an
14
3
2
ic
er
Am
1
of
ty
er
op
Pr

DISASSEMBLY
DISASSEMBLY
s
ne
FIGURE 4: Remove pinion ring nut (2).
FIGURE 1: Remove the retainer screws (6) and washers (7).
rli
18
Ai
5 5
an
ic
er
Am
11 FIGURE 5: Position the cover under a press, extract the pi-

nion (18) complete with the internal bearing (16), the spacer
FIGURE 2: Remove shims (11) and pinion support (5). (15), and shims (14).
Refer and keep to the positions marked during disassembly.
of
NOTE:
body (5).
ty
er
op
4
Pr
T1
FIGURE 3: Stop wrench and rotate the pinion so as to release

and remove the ring nut (2).
FIGURE 6: Remove sealing ring (13) and bearing (4).

DISASSEMBLY
15 14
13
s
ne
FIGURE 7: Remove spacer (15) and calibrated spacer (14). FIGURE 10: Remove sealing ring (13).
rli
Ai
18
16
an
ic
er
Am
FIGURE 8: Position the pinion (18) under a press, remove the

bearing (16).
of
ty
16
er
op
Pr
FIGURE 9: With the help of an extractor, remove the thrust

blocks (4)(16).

ASSEMBLY
ASSEMBLY
5
4
T2
13
16
s
ne
FIGURE 14: Using a surface plate, position the pinion sup-
5 port (5) on the outer bearing (16) and then insert the outer be-
FIGURE 11: Lubricate the outer surface of the new sealing aring (4) in the pinion support (5).
rli
ring (13) and fit it onto the cover (5) using tool T2 (See drawing
T2 p. 72) .
Ai
B
4 16
an
T3
ic
er
Am
FIGURE 15: Arrange accurately the pinion bearings.

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FIGURE 12: Using tool T3 (See drawing T3 p. 72), insert the

thrust blocks of bearing (4)(16).
5
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A
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15
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4
FIGURE 16: Insert depth gauge “DDG” into pinion support (5)
and measure variation “H” in relation to the zero setting per-
formed back at Figure 13.
FIGURE 13: Introduce a spacer (15) and thicker calibrated H = 1,8 mm
spacer between bearings. Reset the depth gauge on pinion
bearings (4)(16) and pinion spacer arranged (15) as in the fi-
gure above.

ASSEMBLY
100° 18
16
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FIGURE 17: Heat the inner bearing (16) to about 212 F° [100 FIGURE 20: Oil seal ring lips.
C°] and fit it to the pinion (18).
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S1=H+X H= A-B X = fix value 0,10 mm
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ic 5
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19
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FIGURE 21: Insert the cover (5).

FIGURE 18: Deviation “H” must be added to a set value of
0,10 mm to obtain calibrated shim “S1” (14) for insertion
between inner bearing cone (4) and spacer (15).
100°
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EXAMPLE: S1=H+X= 1,8 + 0,1 = 1,9 mm
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4
14 15
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5
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FIGURE 22: Heat the outer bearing (2) to about 212 F° [100
C°] and fit into the pinion (1).
FIGURE 19: Insert spacer (15) and two calibrated spacers

“S1” (14).

ASSEMBLY
140-190 N·cm
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FIGURE 23: Insert spacer (3). FIGURE 26: Apply onto the pinion (18) the special tool T1
(See drawing T1 p. 71) and with the help of a torque meter,
check the torque of the pinion (18).
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Loctite 242 Torque: 140 - 190 Ncm
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CAUTION
If torque exceeds the maximum value, then the size of shim
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“S1” (14) between the bearing (4) and the spacer (15) needs
to be increased. If torque does not reach the set value, in-
crease the torque setting of the ring nut (10) in different sta-
ic
ges to obtain a maximum value of 600 - 800 N·m.
er
2 shim “S1” (14) needs to be reduced.
When calculating the increase or decrease in size of shim
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FIGURE 24: Apply Loctite 242 to the thread of the pinion ring “S1”, bear in mind that a variation of shim of 0.01 mm cor-
nut (10) and tighten the nut onto the pinion. responds to a variation of 60 Ncm in the torque of the pinion
(18).
600 - 800 N·m

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25 mm
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T1
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5
FIGURE 25: Lock the wrench T1 (See drawing T1 p. 71), ro-
tate the pinion using a torque wrench, up to a minimum requi- FIGURE 27: CALCULATING PINION CENTER DISTANCE
red torque setting of 600 - 800 N·m. Using a faceplate, reset a dial indicator “DG” on a calibrated
block (whose known thickness is 25 mm).

ASSEMBLY
O-ring
12
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FIGURE 28: Bring internal bearing (2) under dial indicator FIGURE 31: Install a new seal-ring (12). Lubricate the seal
“DG”, test the difference for calculating D. ring before fitting.
D= 25+H = 25+0,5 = 25,8mm
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5
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Y
INT 153
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11
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FIGURE 32: Install shims (11) and cover (5).

Loctite 270
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as “Y” to obtain the actual center distance “I”.

EXAMPLE: I = INT ± Y = 153 - 0,1= 152,9 mm 6
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FIGURE 33: Secure in position with the screws (6) and wa-
shers (7) coated with Loctite 270.
FIGURE 30: Shims “S” for insertion:

S = ( I + D ) - X = ( 152,9 + 25,5 ) - 178 = 0,7 mm
I = actual pinion center distance
D = Bearing distance
X= 178 mm = Fix Dimension

ASSEMBLY
129 - 143 N·m
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FIGURE 34: Using the criss-cross method tighten to torque
of 129 - 143 N·m.
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O-ring
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FIGURE 35: Install a new seal-ring (1).

Lubricate the seal ring before fitting.
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129 - 143 N·m

Loctite 242
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FIGURE 36: Re-fit the reduction unit onto the axle. Fasten the
support planes (turn flange to assist assembly).
Insert nuts by applying LOCTITE 242.
Tighten nuts using a torque wrench setting of 129 - 143 N·m.

T1
P/N: 910.04.2377
Ø 112
- 0,1
Ø 57,5h7 Materiale - Material: vedi nota A - see note A Materiale - Material: vedi nota A - see note A Ø 57,5 - 0,15
Acciaio - Steel 39NiCrMo3 EN10083-1 Acciaio - Steel 39NiCrMo3 EN10083-1
Ø 30
SPECIAL TOOLS
Pr
16
30
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5 x15∞
50
0.8
45∞
90
Materiale - Material: vedi nota B - see note B
ASM-0007E - 123 Axle Service Manual

Acciaio - Steel C40 EN10083
100
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0.8
10
5 x15∞
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5
Ø 88
15
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+ 0,2
85,5 0
11
Write code 910.04.0926
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R2
Usare chiave a bussola
0 USAG 235 3/4" EN n∞27
7 - 0,2 UNI-ISO 2725 - DIN 3124
Use square drive socket
20
Ø92,5 + 0,2 USAG 235 3/4" EN #27

0 UNI-ISO 2725 - DIN 3124
er 40
Ø93
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20
13,59∞
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SCANALATO - SPLINE
45∞
58x53 DIN 5482
N∞ Denti - Teeth n∞ Z= 27
Modulo - Modul m= 2
100 Angolo di pressione - Pressure angle a= 30∞
300 Scost. profilo - Addendum mod. xm= - 0,518
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Diametro rulli - Pins diameter Ø3,5
Quota rulli - Measuring btw pins Md= 59,55-59,60
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Nota A - Note A : Nota B - Note B :
Nitrurato - Nitrured Brunito - Burnished
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SPECIAL TOOLS
Dana Holding Corporation 71

SPECIAL TOOLS
T2
P/N: 910.04.1691
- 0,4
Ø 125 - 0,6
M16
2x45∞
25
12,2 - 0,1
0
11 +0,1
s
-
3x15∞
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1.6
1.6
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+ 0,1
Ø 90 0
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0
Ø 103 - 0,1
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T3
P/N: 910.04.1690
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30∞
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45∞ R2
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45∞
45∞
124,5 - 0,1
0
- 0,1
0
R
of R2
2
+ 0,2
19,5 + 0,1
118
65
40
65
Ø
Ø
Ø
Ø
Ø
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Pr
60
2 x45∞ 10
0.8
+0,1
90
-
115

SWINGING SUPPORT
EXPLODED VIEW
Bushing cut position
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2
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DISASSEMBLY
DISASSEMBLY
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3 FIGURE 4: Remove the screws.
FIGURE 1: Remove the swinging support (3).
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3 FIGURE 5: Disjoin the cover from the differential box by alter-

natively forcing a screwdriver into the appropriate slots.
FIGURE 2: Remove the swinging support (3) on the side op-
posite the drive.
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FIGURE 6: Check condition and position of the cylinder's o-

ring.
FIGURE 3: Position the swinging support (3) under a press
and remove the complete bushing (4).

ASSEMBLY
ASSEMBLY
reference direction A
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FIGURE 7: Install the cover.
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Loctite 242
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104 - 128 N·m
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3
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and insert the complete bushing (4).
FIGURE 8: Lock the cover by tightening the screws.

Torque wrench setting for screws: 40 - 50 N·m
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3 3
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FIGURE 11: Install both swinging supports (3).
reference direction A NOTE:

FIGURE 9: If the bushing (4) is worn and needs replacing, wri- Check that it is properly oriented.
te down the assembly side of the connection notch “ A “.

ASSEMBLY
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SERVICE BRAKE AND NEGATIVE PARKING BRAKE
EXPLODED VIEW
1
2
3 6
5
7
4 8
26
9 10
11
25
32
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12
13
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24
14
15
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23
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17 16
18
27 22 19
21
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20
28
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29
30
31
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RELEASE
RELEASE ADJUSTMENT
Tecno Lube 101
29
30
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31
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FIGURE 4: Remove screws complete with nuts and seals.
Replace seals, apply silicone-based Tecno Lube /101 grease
FIGURE 1: Loosen nuts (30) of screws (31) provided for the
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to the screws and install all parts into the arm.
mechanical and manual release of the braking units, then
move the nuts backwards by approximately 8 mm.
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34 mm
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FIGURE 5: Adjust screws (31) to obtain a distance of 34 ± 0.5

FIGURE 2: Tighten screws (31) so as to fasten them onto the
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mm between axle machined surface and screw.

pressure plate (23).
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30 31
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FIGURE 3: Using a wrench, tighten the screws (31) in an al- FIGURE 6: Lock into position with nuts (30).
ternate sequence by 1/4 turn at a time so as to compress the
Belleville washers (1) and disengage the braking disks.
CAUTION
CAUTION Hold screws (31) into position while locking the nuts (30); af-
ter locking, check the distance of screws (31) once more.
Tighten maximum by one turn.

DISASSEMBLY
DISASSEMBLY
21 - 35 Bar
12
13 13
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FIGURE 10: Remove the reversal springs (13).
FIGURE 7: Connect an external pump to the union piece “P1“
of the negative brake and introduce a pressure of 21 - 35 bar
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to eliminate the pressure of the Belleville washers (1).
23
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21
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31
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FIGURE 11: Remove the adjusting screws (21) from the

counterwasher (23).

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hoist. Loosen and remove screws (31) .

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23
FIGURE 12: Write down the order of assembly and remove
the counterwasher (23).
FIGURE 9: Remove arm together with brakes and axle shafts;

lay down the arm vertically. Release pressure.

DISASSEMBLY
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FIGURE 16: Remove the Belleville washers (1).
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FIGURE 13: Loosen the studs in an alternate manner and re-
move them.
NOTE:
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Check the sense of direction of washers (1).
24
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2
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FIGURE 14: Remove the cylinder (24).

FIGURE 17: The o-rings (2) must be replaced each time the
unit is disassembled.
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26
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Service Brake
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FIGURE 15: Remove the centering device (26) in the cylinder.

CAUTION
damaged.

DISASSEMBLY
17
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FIGURE 19: Write down their order of assembly.
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FIGURE 22: Remove the flange (17) complete with the discs
(20, 19, 18).
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14
3
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Down 15
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17 16
18
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20
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CAUTION 27
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damaged.
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28
FIGURE 23: Remove spacer-braking discs (27) and shims
(28), noting down direction of assembly.
NOTE:
Build a stack of washers and check the measurement.
FIGURE 21: Remove braking discs (14, 15, 16), noting down
direction of assembly.
NOTE:
If disks are not being replaced, avoid changing their posi-
tion.

ASSEMBLY
ASSEMBLY
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the cylinder (24).
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NOTE:
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quence.
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24 11
4 ic
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25
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FIGURE 24: Complete installing the o-rings and anti-extru-

sion rings on all pistons.
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CAUTION FIGURE 27: Fit o-ring (9) and anti-extrusion ring (10) onto the
The o-rings always have to be assembled from the pressure piston (11).
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facing side. Lubricate the piston and the o-rings and install the unit into
the cylinder (24).
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11
3
10 Out Side
Pr
Down
23 Down
9
FIGURE 25: Check the position of the anti-extrusion (4) and

o-rings (2) (25). FIGURE 28: ATTENTION: The o-rings always have to be as-
Lubricate the piston and the o-rings and install the unit (3) into sembled from the pressure facing side.
the cylinder (24) .

ASSEMBLY
2
11
24
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FIGURE 29: Using a plastic hammer, install the piston (11) FIGURE 32: Check condition and position of the cylinder's o-
into the cylinder (24). ring (2).
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NOTE:
24
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quence.
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1
24
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DOWN
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FIGURE 33: Engage the cylinder (24).
NOTE:
Grease
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Check the sense of direction of washers (1) and relative

FIGURE 30: Position the Belleville washers (1) and engage centering.
the cylinder (24).
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NOTE: Loctite 242

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Check the sense of direction of Belleville washers (1) and

relative centering.
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26
FIGURE 34: Insert the screws and tighten them alternately.

Lock the cylinder.
FIGURE 31: Install the centering device (26) in the cylinder.

ASSEMBLY
Negative Brake
Service Brake
30 - 35 N·m
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FIGURE 35: Tightening the studs with a torque wrench set to
a torque of 30 - 35 N·m.
22
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Oil filling
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FIGURE 38: Insert the stroke automatic regulation springs
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(22); place them in line with the piston (23).

FIGURE 36: Fill with oil.
Loctite 270
32
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21 - 35 Bar FIGURE 39: If the anti-rotation pin (32) have been removed,
FIGURE 37: Connect an external pump to the negative brake assemble them with Loctite 270 in the position shown above.
and introduce pressure to 21 - 35 bar.

ASSEMBLY
Y
32
Y 21
23
32 Y = BRAKE GAP
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FIGURE 40: Insert the intermediate disc (23) fitting it on the FIGURE 43: Y=brake gap
anti-rotation pins (32). 0,75mm 1,00mm 1,25mm 1,50mm
depending on axle configuration.
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12 Loctite 270
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5 - 7 N·m
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13
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23
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FIGURE 41: Fit the reversal springs (12, 13) on the interme-
diate disk (23). FIGURE 44: Fit the pin screws. Apply Loctite 270 to the thre-
ad. Torque wrench setting: 5 - 7 N·m.
of
Loctite 242
10 - 15 N·m
X
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FIGURE 42: Apply LOCTITE 242 to the thread of the

adjustment screw. Tighten with torque wrench setting of 10 - FIGURE 45: Take the measurement from the surface of the
15 N·m intermediate disk to the cover sealing surface with 30 bar of
pressure introduced.
EXAMPLE: 29 mm

ASSEMBLY
V 1000Kg
S 28
s
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FIGURE 46: Put the brake disc pack including the shim under FIGURE 49: Insert under the shim washer a thickness of
a press, load with 1000 kg and take the measure “V”. shims (28).
EXAMPLE: V = 42,33 mm
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first disc
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20
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74 mm
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Arm fix quote = 74 mm

FIGURE 50: Install the friction disc (20) on the flange (17) from
FIGURE 47: Arm fix quote = 74 mm arm side.
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Y=brake gap second disc
19
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28 S
S = 74mm - (x + y + v)
FIGURE 48: S = 74 mm - ( x + y + v ) = Thickness of shims to FIGURE 51: Install the metal disc (19) on the flange (17) from
insert under the shim washer. arm side.
EXAMPLE: 74 mm -(29 + 42.33 + 1.25) = S = 1.42 mm

ASSEMBLY
18
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FIGURE 52: Install the friction disc (18) on the flange (17) from FIGURE 55: Check condition and position of the cylinder's o-
arm side. ring.
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16
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FIGURE 53: Insert on the flange the discs (16, 15, 14). FIGURE 56: Check condition and position of the arm's o-ring;
install the complete arm.
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NOTE:
Loctite 242
To assist axle shaft centering, slightly move the wheel
30 - 35 N·m
hub.
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FIGURE 54: Apply Loctite 242 to the studs and tighten it

using a torque wrench.
Torque wrench setting: 30 - 35 N·m Loctite 242
200 - 221 N·m
FIGURE 57: Cross tighten the nuts in two stages.
Torque wrench setting: 200 - 221 N·m

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Copyright 2013 Dana Holding Corporation For product inquiries or support,

All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445
be reproduced in whole or in part by any means, For other service publications,
electronic or otherwise, without prior written approval. visit www.SpicerParts.com/literature.asp
THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
RESALE, AND THIS NOTICE MUST REMAIN ON ALL visit www.SpicerParts.com/order.asp
COPIES.
Service Manual
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Axle
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223
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ASM-0029E
September 2013
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CONTENTS
INTRODUCTION ................................................................................................................................ 5
SPECIFICATIONS .............................................................................................................................. 6
DEFINITION OF VIEWPOINTS .................................................................................................................................... 6
DATA PLATE .............................................................................................................................................................. 6
CONVERSION TABLES ................................................................................................................................................... 7
TORQUE SPECIFICATIONS ............................................................................................................................................ 8
COARSE PITCH ......................................................................................................................................................... 8
FINE PITCH ................................................................................................................................................................ 8
WHEEL NUT TIGHTENING TORQUES ...................................................................................................................... 9
MAINTENANCE ................................................................................................................................................................ 10
MAINTENANCE POINTS ............................................................................................................................................ 10
MAINTENANCE INTERVALS ...................................................................................................................................... 11
ADJUSTMENT AND CHECKS .................................................................................................................................... 11
LUBRICANT & SEALANT SPECIFICATIONS ............................................................................................................. 12
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SAFETY PRECAUTIONS ................................................................................................................... 13
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PLANETARY REDUCTION GEAR .................................................................................................... 15
EXPLODED VIEW ............................................................................................................................................................. 15
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DISASSEMBLY ................................................................................................................................................................ 16
ASSEMBLY ...................................................................................................................................................................... 20
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SPECIAL TOOLS .............................................................................................................................................................. 24
T1 ............................................................................................................................................................................... 24
T2 ............................................................................................................................................................................... 24
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T3 ............................................................................................................................................................................... 25
T4 ............................................................................................................................................................................... 26
T5 ............................................................................................................................................................................... 27
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T6 ............................................................................................................................................................................... 28
COMPLETE STEERING CASE .......................................................................................................... 29
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EXPLODED VIEW ............................................................................................................................................................. 29
DISASSEMBLY ................................................................................................................................................................ 30
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ASSEMBLY ...................................................................................................................................................................... 31
STEERING CYLINDER ...................................................................................................................... 33
EXPLODED VIEW ............................................................................................................................................................. 33
DISASSEMBLY ................................................................................................................................................................ 34
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ASSEMBLY ...................................................................................................................................................................... 37
SPECIAL TOOLS .............................................................................................................................................................. 43
T1 ............................................................................................................................................................................... 43
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T2 ............................................................................................................................................................................... 43
U-JOINT ............................................................................................................................................. 45
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EXPLODED VIEW ............................................................................................................................................................. 45

DISASSEMBLY ................................................................................................................................................................ 46
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ASSEMBLY ...................................................................................................................................................................... 47
SPECIAL TOOLS .............................................................................................................................................................. 48
T1 ............................................................................................................................................................................... 48
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T2 ............................................................................................................................................................................... 48
BRAKE WEAR CHECK PROCEDURE .............................................................................................. 49
OLD VERSION ................................................................................................................................................................. 49
NEW VERSION ................................................................................................................................................................. 50
SPECIAL TOOLS .............................................................................................................................................................. 51
T1 ............................................................................................................................................................................... 51
SERVICE BRAKE AND NEGATIVE PARKING BRAKE .................................................................... 53
EXPLODED VIEW ............................................................................................................................................................. 53
DISASSEMBLY ................................................................................................................................................................ 54
ASSEMBLY ...................................................................................................................................................................... 57
RELEASE ......................................................................................................................................................................... 63
ADJUST ........................................................................................................................................................................... 63

DIFFERENTIAL UNIT ........................................................................................................................ 65
EXPLODED VIEW ............................................................................................................................................................. 65
DISASSEMBLY ................................................................................................................................................................ 66
ASSEMBLY ...................................................................................................................................................................... 70
SPECIAL TOOLS .............................................................................................................................................................. 75
T1 ............................................................................................................................................................................... 75
BEVEL PINION ................................................................................................................................... 77
EXPLODED VIEW ............................................................................................................................................................. 77
DISASSEMBLY ................................................................................................................................................................ 78
ASSEMBLY ...................................................................................................................................................................... 81
SPECIAL TOOLS .............................................................................................................................................................. 86
T1 ............................................................................................................................................................................... 86
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T2 ............................................................................................................................................................................... 87
T3 ............................................................................................................................................................................... 87
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T4 ............................................................................................................................................................................... 88
T5 ............................................................................................................................................................................... 89
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LIMITED SLIP DIFFERENTIAL UNIT 45% ....................................................................................... 91
EXPLODED VIEW ............................................................................................................................................................. 91
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DISASSEMBLY ................................................................................................................................................................ 92
ASSEMBLY ...................................................................................................................................................................... 94
SWINGING SUPPORT ....................................................................................................................... 95
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EXPLODED VIEW ............................................................................................................................................................. 95
DISASSEMBLY ................................................................................................................................................................ 96
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ASSEMBLY ...................................................................................................................................................................... 97
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INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on
efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have
been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is
necessary to assemble only individual components, when partial repair work is needed. The manual provides a
quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the ope-
rations, allows accurate work to be performed.All the information needed for correct disassembly, checks and as-
sembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the
manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is pre-
sumed that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use pro-
per equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and
specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly
s
clean the unit, removing any encrusted or accumulated grease.
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INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate
products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly
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check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (o-rings,
oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time
Ai
a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge.
In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other
one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained.
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CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification
is indicated as follows:
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= up to the part number
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= from the part number on
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When no classification is given, disassembly and assembly operations are the same for all versions.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair
work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or
of
directly from the Service Centers or Authorized Distributors of SPICER.

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SPECIFICATIONS
DEFINITION OF VIEWPOINTS
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DATA PLATE
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1 2
3
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MFG. BY CLARK-HURTH COMPONENTS S.P.A.

38062 Arco (Trento)
MADE IN ITALY
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1 - Type and model unit - modification index

2 - Serial number
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3 - Lubricant
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CONVERSION TABLES
CONVERSION TABLES
UNITS OF PRESSURE
1 ATM=1 BAR=105 PA=14.4 PSI
UNIT OF WEIGHT
N daN kN kg lbs
1N 1 0,1 0,001 0,102 0,225

1daN 10 1 0,01 1,02 2,25
1kN 1000 100 1 102 225
s
1kg 9,81 0,981 0,00981 1 2,205
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UNITS OF TORQUE
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N·m daN·m kN·m kg·m lb·in
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1N·m 1 0,1 0,001 0,102 8,854
1daN·m 10 1 0,01 1,02 88,54
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1kN·m 1000 100 1 102 8854
1kg·m 9,81 0,981 0,00981 1 86,8
1 lb·in 0,1129 0,01129

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0,0001129 0,01152 1
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COARSE PITCH

M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m
M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m
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M27 x 3 mm 998 – 1103 N·m 1088 – 1202 N·m 1411 – 1559 N·m
ic 1539 – 1701 N·m 1710 – 1890 N·m 1838 – 2032 N·m
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FINE PITCH
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M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m
M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m
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Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material.
RECOMMENDED WHEEL NUTS TORQUE
CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY
ST 37 **ST 52
WHEEL NUTS WITH M18 x 1,5 mm 330 N·m 460 N·m

INTEGRATE
M20 x 1,5 mm 490 N·m 630 N·m
SPHERICAL COLLAR
M22 x 1,5 mm 630 N·m 740 N·m
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FLAT COLLAR WHEEL M18 x 1,5 mm 270 N·m 360 N·m
NUTS WITH SEPARATE
M20 x 1,5 mm 360 N·m 450 N·m
SPHERICAL LOCK
WASHER
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M22 x 1,5 mm 460 N·m 550 N·m
WHEEL NUTS WITH IN- M18 x 1,5 mm 260 N·m 360 N·m
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TEGRATE SEAT
M20 x 1,5 mm 350 N·m 500 N·m
CAPTIVE WASHER
M22 x 1,5 mm 450 N·m 650 N·m
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**RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS. IT IS THE OPTIMUM MA-
TERIAL FOR TIGHTENING THE RIM TO THE HUB.
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NOTE:
The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant).
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NOTE:
The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of
the rim material.
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THE DANA OFFICIAL TIGHTENING TORQUE TABLE, THAT IS INCLUDED IN EACH SERVICE MANUAL, SHOWS THE TORQUE FIGURE
RELATED TO THE BOLT CHARACTERISTIC ONLY.
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DANA OFFICIAL TIGHTENING TORQUE TABLE

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NUT MATERIAL QUALITY 8.8 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE
M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m

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M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m
M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m

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*THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY
(DANA AXLES ARE 10.9 ONLY).

MAINTENANCE
MAINTENANCE
MAINTENANCE POINTS
4 4
4
s
1 3
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1 3
2 4 2 4 2
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1 3
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1 - Oil filling plug

2 - Oil draining plug
3 - Check level plug
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4 - Check brake disc wear

Minimum thickness between counter discs is 5.2 mm.
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NOTE:
For details see BRAKE WEAR CHECK PROCEDURE p. 49.
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MAINTENANCE
MAINTENANCE INTERVALS
OPERATION FREQUENCY LUBRICANTS
Differential Monthly SAE85W90 (API GL4 - MIL L-2105)

Check levels With additives for oil-bath brakes
Planetary reduction Every 200 hours
Differential Every 800 hrs * SAE85W90 (API GL5 - MIL 2105-B)

With additives for oil-bath brakes, for units
Oil change Planetary reduction Every 1000 hrs *
presenting hypoid crown wheel and pinion
L.S. Differential Every 700 hrs */** and/or self-locking differential gear
If working in severe duty conditions half intervals should be used
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** When it starts sounding noisy
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OPERATION MEMBER LUBRICANTS CONDITIONS FREQUENCY
King Pin Tapered Bearings
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NLGI 2 EP or NLGI 3 EP*
Seals Normal work Weekly
Greasing
King Pin Bushings NLGI 2 EP or NLGI 3 EP* Severe duty Daily
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Trunnion Bushings w/Moly Additive
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*According to DIN 51825 level KP2K-30 (NLGI #2) or KP3K-20 (NLGI #3); ASTM D4950 NLGI #2 GC-LB
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ADJUSTMENT AND CHECKS
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UNIT OPERATION FREQUENCY SERVICE BRAKE CIRCUIT
Negative brake Adjustment Every 1000 hours*

Only for mineral oil use e.g. ATF Dexron II. Make
Service brake Adjustment Every 500 hours sure that master cylinder seals are suitable for mine-
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ral oil.
Wheel nuts Tightening Every 200 hours**

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** Initially after 10 working hours

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MAINTENANCE
LUBRICANT & SEALANT SPECIFICATIONS

1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate repla-
cement with similar products marketed by different brand names with different trade marks.
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Be-
fore using it, completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
s
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubri-
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cant by using the specific activator.
To remove parts, it may be necessary to heat them at 80° C approximately.
LOCTITE 275
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Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for
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pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum dia-
metrical clearance of 0.25 mm.
LOCTITE 510
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Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal
clearances between flanges up to 0.2 mm. ic
LOCTITE 577
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it,
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remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so
heating may be necessary for larger diameters.
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LOCTITE 638
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with clearance ranging between 0.1 and 0.25 mm.
LOCTITE 648
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Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together
parts with radial clearance below 0.1 mm.
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AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS)

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Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter
of sealing rings for rotating shafts with outer metal reinforcement.
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SILICONE
Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and phy-
sical elements. Polymerises with non-corrosive dampness.
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TECNO LUBE/101 (SILICONE-BASED GREASE)

Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
MOLIKOTE (DOW CORNING)
Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sti-
cking and oxidation of parts that are not lubricated on a regular basis.
(LITHIUM-BASED) GREASE
Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.

SAFETY PRECAUTIONS
1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po-
sitioned and that the machine is locked lengthways.
4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the igni-
tion key from the machine.
5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure
that all torque wrenches have been checked and calibrated.
6 - Always wear gloves and non-slip rubber shoes when performing repair work.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste
s
and dispose of them according to the relative law provisions obtaining in the country where the axles are being
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overhauled.
9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol,
xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment
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friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some
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of the diagrams.
11 - After repair work has been completed, accurately touch up any coated part that may have been damaged.
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12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.
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MAINTENANCE
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PLANETARY REDUCTION GEAR
EXPLODED VIEW
15
16 7
8
11
12 9 10
14
4
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13
2
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1
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6
5
17
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18 3
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19
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DISASSEMBLY
DISASSEMBLY
1 4
s
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FIGURE 4: Loosen and remove the nuts (4) that lock the gear
safety flange (5).
FIGURE 1: Remove check screws (1) from planetary cover.
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6
3
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FIGURE 5: Remove safety flange (6).

FIGURE 2: Alternately insert a lever in the slots provided and
pry to separate the planetary cover (2) from the steering case
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(3).
5
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FIGURE 6: Remove the complete ring gear flange (5) by using

2 a puller and applying counter pressure to the studs.
FIGURE 3: Remove the complete planetary cover (2).

DISASSEMBLY
7
3
s
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FIGURE 7: Partially extract the wheel hub (7) by using a pla- FIGURE 10: Take out the pins and remove the steering case
stic hammer. (3).
For pin removal details, see PLANETARY REDUCTION GEAR
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NOTE: p. 15.
Hammer alternately on several equidistant points.
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8
FIGURE 11: Remove the snap rings (9).
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FIGURE 8: Remove the external bearing (8).

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7
FIGURE 12: Using a puller, remove the planetary gears (10).
FIGURE 9: Draw out the wheel hub (7).
NOTE:
Write down direction of installation of planetary gears.

DISASSEMBLY
16
12 13
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FIGURE 13: Remove the ring gear (13) snap ring (12). FIGURE 16: Remove inner bearing (16).
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14
8
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FIGURE 17: Remove the outer thrust blocks of bearings (8)

FIGURE 14: Remove ring gear flange (14).
(16) by driving a pin driver in the slots provided on the hub (7).
NOTE:
Hammer alternately to avoid thrust block clamping and
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15 deformation.
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17
17
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FIGURE 15: Remove seal ring (15) from wheel hub (7).
NOTE:
Mark the seal ring position.
FIGURE 18: Using a puller, remove seal ring (17) from stee-
ring case (3).
NOTE:
Write down seal ring orientation.

DISASSEMBLY
T1
18
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FIGURE 19: Using driver T1 (See drawing T1 p. 24), extract
the guide bushing (18) of twin u-joint.
Only if necessary, remove any damaged studs (19), which
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need to be replaced.
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ASSEMBLY
ASSEMBLY
16 15
15
T2
16
18
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FIGURE 23: Install bearing (16).
Apply Arexons seal rubber cement to the outer surface of seal
FIGURE 20: Fit the bushing (18) in the steering case (3) using ring (15).
tool T2 (See drawing T2 p. 24).
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Position the seal ring (15) in the hub (7).
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CAUTION
17
Check ring orientation carefully.
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T3
15
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17
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T5
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15
FIGURE 21: Apply a coat of AREXONS rubber cement to the
outer metal surface of the snap ring (17).
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Position the seal ring and, using tool T3 (See drawing T3

p. 25), fit it in the appropriate seat.
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FIGURE 24: Position tool T5 (See drawing T5 p. 27) and press

CAUTION the seal ring (15) into its seat.
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Check direction of installation carefully.

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7
7
8
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T4
16
T4
7
7
FIGURE 25: Turn the hub over (7), lubricate bearing seat and,
FIGURE 22: Position the wheel hub (7) under a press; lubri-
using tool T4 (See drawing T4 p. 26) install the bearing thrust
cate the outer seat of bearing and, using tool T4 (See drawing
block (8).
T4 p. 26), install the thrust block of bearing (16).

ASSEMBLY
14
12 9
10
13
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FIGURE 26: Fit the flange (14) in the ring gear (13) and lock FIGURE 28: Lock gears (10) into position by installing the
into position with snap ring (12). snap rings (9).
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NOTE:
Check that snap ring (12) is fully inserted in the slot of ring
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gear (13).
3
T6
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10
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9
FIGURE 29: Oil the seal ring and bushing. Slip the steering
2 case (3) onto the twin u-joint and fit the pivot pins and con-
nect the steering bar.
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For details, see PLANETARY REDUCTION GEAR p. 15.

FIGURE 27: Mount gears (10) onto the pins of the planetary
cover (2).
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To insert gears, use tool T6 (See drawing T6 p. 28).

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Loctite 270 Tecnolube 101

CAUTION
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The radiused part of bearings' inner ring must face the bot-
tom of the pin.
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FIGURE 30: Only if studs have been removed. Apply a coat

of Loctite 270 to the fast end of studs (19) and apply Tecno-
lube 101 to ground nut end; tighten studs (19) as far as they
will go.

ASSEMBLY
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FIGURE 31: Install the wheel hub (7) onto the steering case FIGURE 34: Ensure that faces are thoroughly cleaned, and
(3). then mount the safety flange (6).
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FIGURE 32: Install the outer bearing (8). FIGURE 35: Apply Loctite 242 to the studs and tighten nuts
(4).
NOTE: Tighten nuts (4) in two stages using the criss-cross method.
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Initial tightening torque: 250 N·m.

Push the bearing as far as it will go by tapping with a pla-
Final tightening torque: 460 - 465 N·m.
stic hammer all around the rim.
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2
5
FIGURE 36: Fit the planetary cover (2) on the wheel hub (7).
FIGURE 33: Install the complete ring gear flange (5).
NOTE:
To engage the flange (5), use a plastic hammer and ham-
CAUTION
mer alternately on several equidistant points. Check state and position of o-ring (11).

ASSEMBLY
2 1
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FIGURE 37: Lock the planetary cover (2) with screws (1).
Tightening torque for screws: 40 - 50 N·m.
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SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2364
260
25 27 205
30
45
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Ø61. 8
Ø2 5
Ø5 9
Ø4 6
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R7 120 3 x45°
.5
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2 x 45 °
2 x 45 °
R1.5
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P/N: 3348
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35
0. 8
120 30
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Ø6 5 ---- 0.0. 64
Ø6 0 ---- 0.08
0.12
Ø2 5
Ø7 5
Ø4 5
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R1
0
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3 x15°
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0. 8
1. 5 0
-- 0. 2 3 x15°
40 200
250

SPECIAL TOOLS
T3
P/N: 2365
32 32
0
R1
120 30
-- 0. 1
-- 0. 2
-- 0. 2
+0
Ø7 4 ---- 0.0. 64
Ø60. 3
Ø58. 5
Ø2 5
Ø9 0
3x15 °
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3x15 °
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32
6 3. 5 +-- 0,0 2
21 14 215
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250
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SPECIAL TOOLS
T4
P/N: 3265
Ø184
Ø4 0 Ø3 5
12. 5
25
45
32
0
R1
s
20°
176
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131
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5x15 °
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32
-- 0. 1
Ø5 0
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-- 0. 3
Ø178 ic 27. 5
20°
Ø4 5
0. 8
0. 8
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0. 8
Am 20
60
5x15 °
47.631
126
166
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0. 8
Ø50 H7
141
R3
Ø60 H7-p 6
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0. 8
Ø165
0. 8
Ø184
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± 0.03
Ø200

SPECIAL TOOLS
T5
P/N: 2366
Ø180
Ø4 0
30
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140
90
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R1
0. 8 ic
R3
15
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10
48
0. 8
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28
14
0. 8
6. 5
0. 8 Ø140
0. 8
+ 0. 1
Ø154 -- 0. 2
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Ø178
Ø189
Ø205
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SPECIAL TOOLS
T6
P/N: 2378
2 x15 ° 0.8
R3 100 30
Ø51
Ø59
Ø30
s
3 x45 °
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10 15
25
0.8
175
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COMPLETE STEERING CASE
EXPLODED VIEW
8 5
9 4
3
10
2
s
1
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18
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13
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14
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16
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17
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DISASSEMBLY
DISASSEMBLY
8
3
s
15
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FIGURE 3: Using two levers, remove the top articulation pin
(4) complete with front seal (9) and shims (3) .
FIGURE 1: Loosen and remove the capscrews (15, 8) from Pay attention not to damage the surfaces.
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the articulation pin (19, 4).
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19 FIGURE 4: Remove the complete steering case (1).

FIGURE 2: Remove the bottom articulation (19) pin complete
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with front sealing ring (10).

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19
4
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upper articulation pin under articulation pin

ASSEMBLY
ASSEMBLY
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FIGURE 8: Lubricate the unit and the steering case.
1
FIGURE 5: Lubricate the terminal of the u-joint and install the
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steering case (1).
Pay attention not to damage the dust cover rings and the se- 12
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aling rings.
10
0,85 mm 4
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19
under articulation pin
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FIGURE 9: Fit the unit (19) in the steering case (1). Position
the screws (15) and tighten securely.
Check for the correct assembly side of the seal (10).
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FIGURE 6: Prepare a series of shims (3) of 0,85 mm to be as-

sembled under the upper pin (4).
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140 N·m
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3 15
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140 N·m
4
upper articulation pin FIGURE 10: Tighten the new capscrews (15) of the top and
bottom articulation pins in sequence using the criss-cross
method.
Torque wrench setting: 140 N·m
FIGURE 7: Fit a new seal (3) onto the top articulation pin (4).
Lubricate and install the unit in the steering case.
Position the screws (8) and tighten to 140 N·m.
Check the correct assembly side of the seal (3).

ASSEMBLY
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FIGURE 11: Using a lever, check that there is no vertical gap.
30 - 60 N·m
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FIGURE 12: Check the torque of the pins, which has to be

between 30 and 60 N·m.
If the preliminary measured value is too high, the shims have
to be increased.
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STEERING CYLINDER
EXPLODED VIEW
10
11
12A
12
2 8
6
12A
7
12
11
s
1 4
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13
16
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3 14
9 17
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14
2
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11
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10
7 9
2
Pr
1
4
6

DISASSEMBLY
DISASSEMBLY
1
3
5
s
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FIGURE 3: Using a puller, disconnect the tapered pins of the
joints (3) from the steering cases (5).
FIGURE 1: If required, remove the steering piston stroke cen-
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tering sensor (1).
6
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FIGURE 4: Disconnect left and right steering bars from piston

(6).
FIGURE 2: Loosen the check nuts (2) on the joints (3) of the
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steering bars (4). Remove nuts.

CAUTION
NOTE:
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To ease bar removal, heat the threaded portion of the piston

Should the joint rotate, hold it with a wrench inserted in to approximately 212 °F [100 °C] with a heat gun.
the seat provided.
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CAUTION 7
The self-locking nuts (2) must be replaced once every 5 di-
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sassemblies.
FIGURE 5: Loosen and remove the steering cylinder (8)

screws (7).

DISASSEMBLY
8
T1
3
5
s
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FIGURE 6: Extract the steering cylinder (8) using a plastic FIGURE 9: Using a punch, force the stop ring (4) located in-
hammer. side the cylinder (3) and extract ring using a screwdriver.
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12
12 10
10 9
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FIGURE 7: Before attempting to disassemble the unit, drain FIGURE 10: Using a plastic hammer, hammer the piston (5)
the oil in the cylinder chambers completely. so it strikes against the head (2).
Using a screwdriver, remove the snap ring (1) of the cylinder Continue until the head (2) is ejected from the cylinder (3).
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head (2).
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12
12 10
10 9 T1
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11
11 5
5
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FIGURE 11: Take the cylinder unit (3) apart by extracting the
FIGURE 8: Lightly tap the cylinder head (2) with a plastic head (2) first, followed by the piston (5).
hammer to push it inside the cylinder (3).
NOTE: CAUTION
Insert the cylinder head so it is flush with the cylinder.
Write down direction of installation of piston whose seal ring
"A" is oriented towards cylinder head (2).

DISASSEMBLY
3
2
s
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FIGURE 12: Remove all seals, anti-extrusion rings, and scra-
per rings from head (2), cylinder (3) and piston (5).
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NOTE:
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1 - All seals must be replaced at each disassembly.
2 - Pay particular attention not to damage seal seats and
piston beds.
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ASSEMBLY
ASSEMBLY
T1
3
5
s
3
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FIGURE 16: Apply tool T1 (See drawing T1 p. 43) to the pi-
ston rod on non-head side (2) and center rod into cylinder (3)
FIGURE 13: Grease and install the piston rod seal ring (6) and so as to fit it into piston (5).
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scraper ring (7) into cylinder (3).
NOTE:
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Lightly grease seals and cylinder.
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5
FIGURE 14: Grease and install the piston rod seal ring (6) and
scraper ring (7) into the head (2).
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FIGURE 17: Introduce the piston (5) into the cylinder by ap-
proximately 150 mm using a plastic hammer.
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FIGURE 15: Prepare piston (5) by fitting it with guide ring (9), 5
magnetic ring (10), o-ring (11), and seal (12).
CAUTION FIGURE 18: Remove tool T1 (See drawing T1 p. 43) and ap-
ply it to the opposite side of the piston (5).
1 - To ease installation, lubricate with grease.
2 - If a centering sensor is not required, the magnetic ring
(10) can be replaced with an additional guide ring (9).

ASSEMBLY
3 2
2
s
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FIGURE 19: Grease the seals of the head (2), slip the head FIGURE 22: Fit the snap ring (1) of head (2).
onto the piston and, using a plastic hammer, introduce head If necessary, force it into the seat with a punch and hammer.
into cylinder (3).
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NOTE: CAUTION
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Introduce the head so it is flush with the cylinder.
Make sure that the snap ring (1) fits snugly in its seat.
4
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FIGURE 20: Introduce the stop ring (4) and ensure that it sets
FIGURE 23: Check the condition of the axle unit's o-rings (9).
in the seat of cylinder (3).
Grease piston seats with Tecnolube Seal 101 and install
ty
cylinder using a plastic hammer.

er
7 8
op
4
Pr
FIGURE 21: Using two screwdrivers or levers, force the head

until it is seated against the stop ring (4). FIGURE 24: Block cylinder (8) with screws (7) coated with
Loctite 242 and tightened to a torque of 180 - 200 N·m.

ASSEMBLY
19
s
ne
FIGURE 25: Apply Loctite to the threaded portion of the ste- FIGURE 27: If required, install the steering piston stroke cen-
ering bars and connect the bars by tightening the ends in the tering sensor (1) for checking piston centering and tighten
piston rod. screws (13). Tightening torque: 5 - 6 N·m
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Tightening torque: 430 - 470 N·m.
Ai
CAUTION
CAUTION
If required, eliminate the action of the negative brake.
Accurately remove grease from the threads using an activa-
an
tor before applying the thread locking compound.
ic
er
3 B
B
T2
Am
5
2
of
FIGURE 28: Apply tools T2 (See drawing T2 p. 43) onto the

ty
wheel hubs and lock tools.

FIGURE 26: Introduce the pins (3) in the steering cases (5) Check that tools are perfectly flat and parallel to each other
er
and lock into position with nuts (2) tightened to a torque of using a level "B".
350 - 390 N·m.
op
1
Pr
FIGURE 29: Connect the sensor (1) to the control device ac-
cording to either of the following diagrams.

ASSEMBLY
I max=0,80 A
NERO
BLACK C
CONNETTORE
CONNECTOR
2 BLU
1 3
BLUE
--
4
BATTERIA
BATTERY
MARRONE
BROWN
+
2A
s
FIGURE 30: Sensor wiring diagram for STANDARD version.
ne
FIGURE 33: Check distance "C" of piston on either of the two
sides and write down distance dimension to check subse-
I max=0,80 A quent adjustments.
rli
NERO
BLACK NOTE:
Ai
CONNETOR For cylinders without sensors, piston must be centered
CONNECTOR BATTERIA based on maximum stroke.
2 BATTERY
BLU
--
an
1 3
4 BLUE
LL
ic
er
MARRONE
BROWN
+ LL
2A
Am
FIGURE 31: Sensor wiring diagram for OPTIONAL version.
== =
= T2
of
T2
FIGURE 34: Lay level "L" on two upper studs and line them
ty
up. Apply tools T2 (See drawing T2 p. 43) to the two horizon-

tal studs; hold them in position with two nuts, level them, and
er
finally lock into position.

op
Pr
T2
FIGURE 32: Center by slowly moving the piston first in one
direction, then in the opposite one, position the piston in the
middle point of the stroke, which is determined by the control
device signalling lamp turning on and switching off in the re-
verse stage.
T2 T2
FIGURE 35: Without moving the piston, check front and rear
stud between the edges of tools T2 (See drawing T2 p. 43)
maximum allowed difference: 1 - 1.5 mm.

ASSEMBLY
12 Pos. 2 Pos. 4
11
Pos. 3 Pos. 1
STEERING CYLINDER
CILINDRO STERZO
LENKZYLINDER
CILINDRO DE DESVIO
CYLINDRE DE DIRECTION
s
ne
FIGURE 36: TOE-IN FIGURE 39: ADJUSTING THE STEERING ANGLE
If necessary, adjust alignment after loosening the check nuts Loosen the nut of one of the adjusting screws on cylinder si-
(11) of ball pins (12). de.
rli
NOTE:
Ai
12 Perform the same operations on both sides (see dia-
gram).
12A
an
ic
er
Am
B
FIGURE 37: Hold joints (12A) tight and rotate the ball pins (12)
until tools T2 (See drawing T2 p. 43) become parallel to each
of
other.
15 14
NOTE: FIGURE 40: Adjust the jutting portion of the screw (15) accor-
ty
1 - Loosen the nuts by a few turns. ding to data shown in the table.
2 - Half a turn of the pin will reduce the front stud by about Lock into position with nut (14) tightened to 145 - 148 N·m.
er
3 mm and increase the rear one by about 3 mm.

op
12
11
Pr
15
14
FIGURE 41: Perform one full steering operation until the adju-
FIGURE 38: Once toe-in has been adjusted, lock nuts (11). sted screw (15) leans against the arm stop.
Tightening torque for nuts: 328 - 363 N·m.

ASSEMBLY
16
17
14
s
ne
FIGURE 42: While holding the adjustment screw in position
against the arm stop, adjust the screw opposite (16), on non-
cylinder side, until it leans against the arm stop.
rli
Ai
CAUTION
The screws (15) and (16) must lean against the respective
arm stops all at the same time.
an
ic
er
Am
of
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er
op
Pr

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2368
Ø5 0 ---- 0.05
0.10
0. 4
M8 x1.2 5
R2 5°
.5
s
15
ne
30
44
rli
14
75
Ai
7
1
an
1 x45
28 °
ic
Ø6.5
er
0
Ø28. 3 -- 0.05
Ø48. 1 + 0.05
0
Am
T2
P/N: 2367
of
5
R1
ty 23
R 11 0
100
50
er
5 x45°
op
22 40
55 500
Pr
555
17 ±0. 1
63
125
125

SPECIAL TOOLS
s
ne
rli
Ai
an
ic
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Am
of
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op
Pr

U-JOINT
EXPLODED VIEW
4 6
7
9
5
8
1
s
2
ne
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Ai
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Am
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op
Pr

DISASSEMBLY
DISASSEMBLY
1 2 5
s
ne
FIGURE 4: Place the u-joint under a press and remove the
complete bushing (5).
FIGURE 1: Loosen and remove the check nut (1) of the stud
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(2). Remove stud (2).
Ai
6
an
ic 7
8
er
3
Am
FIGURE 5: Remove the bearing (7) snap ring (6).

Remove the o-ring (8) and, using a puller for inner parts, re-
FIGURE 2: Extract the whole twin u-joint (3). move the bearing (7) and seal ring (9).
of
NOTE: NOTE:
If necessary, use a plastic hammer or lever to ease ex- Write down direction of installation of seal ring.
ty
traction of the twin u-joint.

er
op
Pr
FIGURE 3: Remove the snap ring (4) of the bushing kit (5).

ASSEMBLY
ASSEMBLY
CAUTION
Tap around the whole rim.
T1 T2
5 4
s
ne
FIGURE 6: Using tools T1 (See drawing T1 p. 48) and T2 (See
drawing T2 p. 48), introduce the seal ring (9) and bearing (7)
5
rli
into the bushing (5).
FIGURE 9: Install the bushing (5) snap ring (4); position the o-
Ai
NOTE:
ring (8) as well.
Check direction of installation of seal (9) carefully.
an
ic 2
er
6
Am
7
3
of
FIGURE 7: Install the bearing (7) snap ring (6). FIGURE 10: Introduce the twin U-joint (3) into the arm and
lock into position with stud (2) coated with Loctite 242.
ty
Tighten stud to a maximum torque of 15 N·m.

er
1 2
op
1 2
5
Pr
FIGURE 8: Install the complete bushing (5) onto the twin u-

joint and set bushing into position with a plastic hammer.
FIGURE 11: Apply Loctite 242 to the jutting portion of the
stud (2) and tighten nut (1).
Tighten nut (1) to a torque of 60 - 70 N·m while holding stud
(2) in position.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 3342
100 30
0.8 0.8
0. 8
Ø54, 5 -- 0.0 1
Ø9 0 -- 0.15
Ø5 4 + 0.0 1
Ø7 9
Ø3 0
s
ne
3 x45°
R1
0. 8
rli
3 x15°
Ai
0. 8
an
2,5 -- 0.0 2
14 10 120 ic
er
T2
Am
P/N: 2301
10
1. 5 x45°
of
R1
0. 8
100 30
ty
er 49. 5
Ø3 0
89
op
3 x45°
R1
0
Pr
0. 8
130
155

BRAKE WEAR CHECK PROCEDURE
OLD VERSION
CAUTION
35 - 50 N·m
FIGURE 4: Install the oil drain plug.
s
ne
Fill with oil.
rli
Ai
FIGURE 1: Remove the oil drain plug and discharge oil.
an
ic
T1
er
Am
of

ty

er
CAUTION
op

both sides if necessary. See SERVICE BRAKE AND NEGA-
TIVE PARKING BRAKE p. 53.
Pr

gauge.

SPECIAL TOOLS
NEW VERSION
CAUTION
35 - 50 N·m
s
FIGURE 4: Install the inspection plug.
ne
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Ai
FIGURE 1: Remove the inspection plug.
an
ic
er
Am
T1
of

ty

er
CAUTION
op

both sides if necessary. See SERVICE BRAKE AND NEGA-
Pr
TIVE PARKING BRAKE p. 53.

gauge.

SPECIAL TOOLS
SPECIAL TOOLS
T1
5.2
°
45
1
25
32
32
s
ne
rli
Ai
an
160
110
8
ic
er
Am
of
32
32
25
1
ty
er
10
45
5.4
op
Pr

SPECIAL TOOLS
s
ne
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Ai
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Pr

SERVICE BRAKE AND NEGATIVE PARKING BRAKE
EXPLODED VIEW
1
2
3 6
5
7
4 8
26
9 10
11
25
s
12
ne
13
24
14
rli
15
23
Ai
17 16
18
27 22 19
an
21
20
28 ic
er
29
30
Am
31
of
ty
er
op
Pr

DISASSEMBLY
DISASSEMBLY
21-35 Bar
13
13
12
12
13
13
s
ne
FIGURE 4: Remove the adjusting screws (13) from the
counterwasher (23).
FIGURE 1: Connect an external pump to the union piece “P1“
rli
of the negative brake and introduce a pressure of 21 - 35 bar
to eliminate the pressure of the Belleville washers (1).
Ai
31
an
31 ic
er
21
Am
FIGURE 5: Remove the pin screws (21).
23
23
of

hoist.
Loosen and remove screws (31).
ty
er
op
Pr
Down
FIGURE 6: Write down their order of assembly and remove
the counterwasher (23).
FIGURE 3: Remove arm together with brakes and axle shafts;

lay down the arm vertically. Release pressure.

DISASSEMBLY
1
1
s
FIGURE 10: Remove the Belleville washers (1).
ne
FIGURE 7: Loosen the studs in an alternate method and re-
move them.
NOTE:
rli
Check the sense of direction of washers (1).
24
24
Ai
an
22
ic
er
Am
FIGURE 8: Remove the cylinder (24).

FIGURE 11: The o-rings (2) must be replaced each time the
unit is disassembled.
of
ty
11
26
26
er
op
Service Brake
Pr
FIGURE 9: Remove the centering device (26 ) in the cylinder.

CAUTION
damaged.

DISASSEMBLY
24
16
s
FIGURE 13: Mark the assembly position.
ne
FIGURE 16: Remove the flange (17) complete with the discs
( 20 , 19, 18) .
rli
14
33
Ai
Down 15
an
17 16
18
19
ic 20
er

Am

of
CAUTION
27
27
ty
damaged.
er
14
op
15
Pr
28
28
FIGURE 17: Remove spacer-braking discs (27) and shims

(28), noting down direction of assembly.
NOTE:
16
16 Build a stack of washers and check the measurement.
FIGURE 15: Remove braking discs (14, 15, 16), noting down
direction of assembly.
NOTE:
If disks are not being replaced, avoid changing their position.

ASSEMBLY
ASSEMBLY
11
11
24
24
CAUTION
The o-rings always have to be assembled from the pressure
facing side.
33
s
Down
ne
FIGURE 20: Fit o-ring (9) and anti-extrusion ring (10) onto the
piston (11).
Lubricate the piston and the o-rings and install the unit into
rli
23
23 Down the cylinder (24).
Ai
11
11
FIGURE 18: Check the position of the anti-extrusion (4) and

Out Side
an
o-rings (2, 25).
Lubricate the piston and the o-rings and install the unit (3) into ic
the cylinder (24).
10
er
10
9
9
Am
FIGURE 21: ATTENTION: The o-rings always have to be as-

33 sembled from the pressure facing side.
of
11
ty
11
er
op
the cylinder (24).
NOTE: 24
Pr
24
quence.
FIGURE 22: Using a plastic hammer, install the piston (11)
into the cylinder (24).
NOTE:
quence.

ASSEMBLY
24
24
11
DOWN
24
24
s
ne
FIGURE 23: Position the Belleville washers (1) and engage FIGURE 26: Engage the cylinder (24).
the cylinder (24).
NOTE:
rli
NOTE: Check the sense of direction of washers (1) and relative
Check the sense of direction of Belleville washers (1) and centering.
Ai
relative centering.
Loctite 242
an
ic
er
26
26
Am
of
FIGURE 27: Insert the screws and tighten them alternately.

FIGURE 24: Install the centering device (26) in the cylinder. Lock the cylinder.
ty
30-35 N·m
er
22
op
Pr
FIGURE 25: Check integrity and position of the cylinder's o- FIGURE 28: Tightening the studs to a torque of 30 - 35 N·m.
ring (2).

ASSEMBLY
23
23
21-35 Bar
s
ne
FIGURE 29: Connect an external pump to the negative brake FIGURE 31: Insert the intermediate disk (23).
and introduce pressure to 21 -35 bar.
12
12
rli
Ai
Negative Brake 13
13
Service Brake
an
ic 23
23
er
Am
FIGURE 32: Fit the reversal springs (12, 13) on the interme-
diate disk (23).
22
22
10-15 N·m
of
Loctite 242
ty
er
23
23
op
Pr
FIGURE 30: Insert the stroke automatic regulation springs

(22); place them in line with the piston (23).
FIGURE 33: Apply LOCTITE 242 to the thread of the
adjustment screw.
Tighten with torque wrench setting of 10 - 15 N·m

ASSEMBLY
1000Kg
Y V
Y 21
V
Y = BRAKE GAP
s
ne
FIGURE 34: Y=brake gap FIGURE 37: Put the brake disc pack including the shim under
0,75mm 1,00mm 1,25mm 1,50mm a press, load with 1000 kg and take the measure “V”.
depending on axle configuration. EXAMPLE: V = 42,33 mm
rli
5 - 7 N·m
Ai
Loctite 270
an
74 m m
ic
er
Am
Arm fix quote = 74 mm

FIGURE 35: Fit the pin screws. FIGURE 38: Arm fix quote = 74 mm
Apply Loctite 270 to the thread.
of
Torque wrench setting: 5-7 N·m.

Y=brake gap
S 28
ty
X
er
op
X
Pr
X
S = 74mm - (x + y + v)
FIGURE 39: S = 74 mm - ( x + y + v ) = Thickness of shims to
insert under the shim washer.
FIGURE 36: Take the measurement from the surface of the EXAMPLE: 74 mm -(29 + 42,33 + 1,25) = S = 1,42 mm
intermediate disk to the cover sealing surface with 30 bar of
pressure introduced.
EXAMPLE: 29 mm

ASSEMBLY
18
18 20
20
19
19
S 28
17
17
20
20
3° Disc
18
18
s
ne
FIGURE 40: Insert under the shim washer a thickness of FIGURE 43: Install the friction disc (18) on the flange (17) from
shims (28). arm side and insert the group on the u-joint.
rli
18
18
16
16
Ai
an
ic
First Disc
er
4° Disc
18
Am
18
16
16
FIGURE 41: Install the friction disc (18) on the flange (17) from
arm side. FIGURE 44: Insert on the flange the discs (16, 15, 14).
of
19
19
ty
er
op
2° Disc
Pr
19
19
FIGURE 42: Install the metal disc (19 ) on the flange (17) from
arm side. FIGURE 45: Check the alignment of last disc (14) and flange
(17).

ASSEMBLY
Loctite 242 / 30 - 35 N·m
Loctite 242 / 200 - 221 N·m
s
ne
FIGURE 46: Apply Loctite 242 to the studs and tighten to 30 FIGURE 49: Tighten the nuts in two stages to 200 - 221 N·m.
- 35 N·m
rli
Ai
an
ic
er
Am
FIGURE 47: Check integrity and position of the cylinder's o-

ring.
of
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op
Pr
FIGURE 48: Check integrity and position of the arm's o-ring;

install the complete arm.
NOTE:
To assist axle shaft centering, slightly move the wheel
hub.

RELEASE
RELEASE ADJUST
Tecno Lube 101
29
30
31
s
ne
FIGURE 53: Remove screws complete with nuts and seals.
FIGURE 50: Loosen nuts (30) of screws (31) provided for the Replace seals, apply silicone-based Tecno Lube /101 grease
rli
mechanical and manual release of the braking units, then to the screws and install all parts into the arm.
move the nuts backwards by approximately 8 mm.
Ai
an
ic 34 mm
er
Am
FIGURE 51: Tighten screws (31) to fasten them onto the pres- FIGURE 54: Adjust screws (31) to obtain a distance of 34 ± 0.5
of
sure plate (23). mm between axle machined surface and screw underhead.
ty
er
op
30 31
Pr
FIGURE 52: Using a wrench, tighten the screws (31) in an al-

ternate sequence by 1/4 turn at a time so as to compress the FIGURE 55: Lock into position with nuts (30).
Belleville washers and disengage the braking disks.
CAUTION
CAUTION Hold screws (31) into position while locking the nuts (30); af-
Tighten maximum by one turn. ter locking, check the distance of screws (31) once more.

ADJUST
s
ne
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Ai
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DIFFERENTIAL UNIT
EXPLODED VIEW
1 2
3 4
7
42 8 9
5 10
19
39 6 17 20
18
s
38
ne
22
12
40 24
13
rli
14
28 29 15 21
Ai
30
41
23 27
37
an
25 26
31
ic
32
er
33
Am
34
36
35
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Pr

DISASSEMBLY
DISASSEMBLY
2 26
T1
s
ne
FIGURE 4: Only if removing or adjusting, use special tool T1
(See drawing T1 p. 75) to mark the position of the ring nuts (2)
FIGURE 1: Sling the arm to be removed and connect it to a and (26).
rli
hoist. Loosen and remove screws and nuts.
Ai
an
ic
er
Am
FIGURE 5: Loosen the stud bolts (35, 41) and remove two of
FIGURE 2: Only if removing or adjusting, remove the screw them.
of
(27).
ty
80C°
er
op
Pr
38 33
FIGURE 6: Disjoin the cover (38, 33) crown side.

FIGURE 3: Only if removing or adjusting, uniformly heat the
ring nuts up to a temperature of 176 °F [80 °C].

DISASSEMBLY
29
s
ne
FIGURE 7: Remove the cover and studs. FIGURE 10: Remove the cap (29).
3 25
rli
Ai
an37 36
ic
er
33 38
Am
FIGURE 8: Extract the whole differential unit. FIGURE 11: If the bearings need replacing, extract the exter-
nal thrust blocks of the bearings (3) and (25) from middle co-
ver (33, 38).
of
NOTE:
30 Accurately check the o-ring (37, 36).
ty
er
op
Pr
3
FIGURE 12: If the bearing needs replacing, extract the bea-

ring (3).

DISASSEMBLY
24
25
23
s
ne
FIGURE 13: If the bearing need replacing, extract the bearing FIGURE 16: Remove the screws (24) joining the differential
(25) from the differential carrier (23). unit half box.
rli
Ai
an
4
23
ic
er
5
Am
FIGURE 14: Remove the ring gear (6) capscrews (4). FIGURE 17: Using a plastic hammer, take the half box (23, 5)
to pieces.
of
NOTE:
42
Write down the coupling marks.
ty
23
er
op
6
Pr
FIGURE 15: Remove the spacer (42) and the ring gear (6).
FIGURE 18: Remove the upper half box (23).

DISASSEMBLY
22
8
21
s
ne
FIGURE 19: Remove shoulder (22) and first planetary gear FIGURE 22: Remove the 2nd planetary gear (8) and shoulder
(21). ring (7).
rli
15 19 18 23 5
Ai
an
14 20 P
ic
SR
Sw
er
Sh
S
Am
FIGURE 20: Remove shafts (18), complete with planetary ge- FIGURE 23: The differential unit.
Sh = Shafts (18)(17)
of
9 13 17 SW = spherical shoulder washers (9)(13)(14)(20)

P = planetary gears (8)(21)
ty
SR = shoulder ring (22)(7)

er
10 12 S = planet wheels (10)(12)(15)(19)

23 = upper half box
op
5 = half box crown side

Pr
FIGURE 21: Remove shafts (17), complete with planetary ge-


ASSEMBLY
ASSEMBLY
22
8
21
s
5
ne
FIGURE 27: Install the planetary gear (21) and shoulder ring
(22).
FIGURE 24: Install the shoulder ring (7) and planetary gear (8)
rli
into the halfbox (5).
23
Ai
9 13 17
10 12
an
ic
er
Am
FIGURE 28: Mount the locking half-box (5) onto the half-box
(23)
of
shoulder washers (9, 13) onto the shafts (17).

Install the planetary set. Loctite 270
ty
15 19 18
er
24
op
14 20
Pr
FIGURE 29: Lock the half box with screws (24) coated with
Loctite 270.
shoulder washers (14, 20) onto the shafts (18). CAUTION
Install the planetary set.
1 - The match marks on the two half-boxes must corre-
spond.
2 - Use only new screws.

ASSEMBLY
80 N·m 150 N·m
24
s
FIGURE 30: Fit the complete differential unit in a vice and FIGURE 33: Lock the ring gear (6) by tightening the screws (4)
ne
tighten the screws (24) holding the two half boxes together to to a torque of 150 N·m using the criss-cross method.
a torque of 80 N·m.
rli
CAUTION
Ai
100°
an
42 ic 3
er
Am
FIGURE 34: INSTALLATION OF THE DIFFERENTIAL UNIT

Position the differential unit under a press and, using a driver
6 with an adequate diameter, install the first bearing (3).
of
FIGURE 31: Install the spacer (42) and the ring gear (6).
ty
100°
Loctite 270
er
25
op
4
Pr
FIGURE 35: Turn the unit upside down and install the second
bearing (25).
FIGURE 32: Mount the ring gear (6) and fasten it to the diffe-
rential box with screws (4).
CAUTION
Pay particular attention; position a shim with adequate dia-
CAUTION meter in order to engage the internal ring of bearing without
engaging the cage.
Use only new screws.

ASSEMBLY
s
ne
FIGURE 36: Only if bearings are replaced, insert the thrust FIGURE 39: Position the differential unit in the central body
blocks of the bearings into the intermediate covers. with the help of a bar and fit the middle cover.
rli
36 37 C
Ai
an
ic
38
er
Am
FIGURE 37: Thoroughly check the condition of the o-ring (36, FIGURE 40: Tighten the two safety screws “C” into the main
37). body (28) and install the intermediate cover (38).
of
Loctite 242 Loctite 242

35 140 N·m 140 N·m
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er
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Pr
33
FIGURE 38: Fit the intermediate cover (33) on opposite side FIGURE 41: Tighten screws to a torque of 140 N·m.
of ring gears: lock cover with screws (35) coated with Loctite
242.
Tighten screws to a torque of 140 N·m.

ASSEMBLY
1/4 turn
T1 2
s
ne
FIGURE 42: Only if ring nuts have been removed, tighten the FIGURE 45: Introduce a gauge “A” with long tracer through
ring nut (2) on ring gear side until clearances between pinion the hole provided for the cap. Position the tracer on the side of
and ring gear are zeroed. Then, loosen by about 1/4 turn. a tooth of the ring gear, approximately 5 mm from the outer
rli
rim; preload by about 1 mm and zero the gauge.
Ai
Gap = 0,25 - 0,33 mm
an
ic
er
T1 26
Am
FIGURE 43: Only if ring nuts have been removed, preload be-
arings with ring nut (26) on non-ring gear side in order to in-
crease the torque of the pinion. FIGURE 46: As you hold the pinion in position, move the ring
of
gear manually in both directions to check clearance between

pinion and ring gear. Standard clearance: 0,25 - 0,33 mm
CAUTION
ty
In the case of used bearings, check thrust torque; in the

er
case of new bearings, check continuous torque.

2 26
op
1 27
Pr
TM
FIGURE 47: If torque and/or pinion-ring gear clearance is not

within tolerance values and the ring nuts have not been remo-
ved, mark the position of the ring nuts (2, 26) and remove the
FIGURE 44: Apply torque meter TM to pinion nut and check
safety plates (1, 27).
that torque will increase by 20 - 40 N·cm as a result of diffe-
rential bearing preload.
Example: pinion torque: 120 - 130 N·cm Pinion + differential
torque: 140 - 170 N·cm.

ASSEMBLY
T1
s
ne
FIGURE 48: Adjusting clearance between pinion and ring gear. FIGURE 51: Install the complete arm.
To INCREASE: loosen the ring nut on ring gear side and tighten
the ring nut on non-ring gear side by the same measure.
283 - 312 N·m
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To DECREASE: perform the same operations inversely. To ro-
tate ring nuts, use special wrench T1 (See drawing T1 p. 75).
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Loctite 242
24 - 26 N·m
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FIGURE 52: Torque wrench setting: 283 - 312 N·m.
NOTE:
Tighten using the criss-cross method.
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FIGURE 49: Engage screw (27) in the slot next to the holes
provided for the check screws.
Coat screws (27) with Loctite 242 and tighten to a torque of
ty
24 - 26 N·m.
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FIGURE 50: Fit the top plug after applying repositionable

jointing compound for seals to the rims. Install the snap ring.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2379
¯ 166
10 x15
¯ 40.5 ---- 0.1
0.2
0.8
¯ 15H7-n6
s
100
¯ 14
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2 x15
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0.8
24
17
20
Ai 238
0
R1 ¯ 25
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¯ 10
¯ 35
123
125
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33
36
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¯ 37H7-n6
¯ 47
of
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¯ 143 0.1
R 30
25
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Pr

SPECIAL TOOLS
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BEVEL PINION
EXPLODED VIEW
3 6
2
14 15
s
17
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7
1
8
13
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9
10 16
11
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12
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DISASSEMBLY
DISASSEMBLY
2
1
10
11 10
s
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FIGURE 1: Remove both axle arms.
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80C°
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10
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1 10 FIGURE 4: Remove the flange (10) complete with guard (2).

Am
FIGURE 2: If disassembly is difficult, heat the check nut (1) of

the flange (10) to 176 °F [80 °C].
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NOTE:
Heat will loosen the setting of Loctite on the nut (1).
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9
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T1 FIGURE 5: Remove the sealing ring (9).
FIGURE 3: Position tool T1 (See drawing T1 p. 86), so as to

avoid pinion rotation.
Loosen and remove the nut (1) and o-ring (11).

DISASSEMBLY
T2
s
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FIGURE 6: Apply blocks T2 (See drawing T2 p. 87) and, with FIGURE 9: Remove the thrust block of the external bearing
the help of a puller, extract the pinion (5) complete with the in- (3).
ternal bearing (6), the spacer (8), and calibrated spacer (4, 7).
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NOTE:
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body (12).
17
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7
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FIGURE 10: Insert a drift in the appropriate holes.

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FIGURE 7: Remove spacer (17) and calibrated spacer (7).

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5
4
Pr
6
6
FIGURE 11: Remove the thrust block of the internal bearing
(6) as well as the shim washers (4).
FIGURE 8: Using a puller and a press, remove the inner bea-

ring (5) from the pinion (6).

DISASSEMBLY
15
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14
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FIGURE 13: Remove the cap (14).

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ASSEMBLY
ASSEMBLY
I = 135
M5
- 0,1 = Y
s
42 mm
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FIGURE 14: CALCULATING PINION CENTER stud as “Y” to obtain the actual center stud “I”.
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Using a faceplate, reset a dial indicator “DG” on a calibrated EXAMPLE: I = 135 - 0.1 = 134.9
block (whose known thickness is 42 mm.).
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Preload the gauge by about 3 mm. NOTE:
M5 = Match part number
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D
9
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FIGURE 15: Bring inner bearing (6), complete with thrust

block, under gauge “DG”. FIGURE 17: Calculate shims "S" for insertion under the thrust
ty
EXAMPLE: 42 +0.5 = 42.5 = “D”. block of the inner bearing using the following formula:
S = 178 - (I+D)
er
where: 178 = fixed dimension;

CAUTION I = actual pinion center stud;
D= total bearing thickness;
op
Press the thrust block centrally and carry out several mea- EXAMPLE: S = 178 - (134.9 + 42.5) = 0.6 mm.
surements by rotating the thrust block.
Pr

ASSEMBLY
T3
A
DDG
A
6
4
T4 T4
3
s
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FIGURE 18: Using special tool T3 (See drawing T3 p. 87) par- FIGURE 21: Introduce the tracer of a depth gauge “DDG” into
tially insert the thrust block of the bearings (3, 6) and shims (4). either side hole of tool T4 (See drawing T4 p. 88). Reset the
gauge with a preload of about 3 mm.
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3
FIGURE 19: Connect the tension rod to the press and move
the thrust block of bearings (3, 6) into the seats. FIGURE 22: Remove the gauge and take out tool and bearing
Disconnect the press and remove the tension rod. kits from the main body.
of
Reinstall every part, also introducing a spacer between bea-

NOTE: rings (3) and (6). Tighten the entire pack by hand.
Before starting the next stage, make sure that the thrust
ty
block has been completely inserted into its seat.

er
T4
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12
Pr
H = A - B = 1,8 mm
3 T4
FIGURE 23: Introduce depth gauge “DDG” in tool T4 (See
drawing T4 p. 88) and measure deviation “H” from the pre-
vious reset.
FIGURE 20: CALCULATING PINION BEARINGS ROLLING
EXAMPLE: H = A - B = 1,8 mm.
TORQUE
Introduce tool T4 (See drawing T4 p. 88) complete with bea-
rings (3) and (6) into the main body (12); tighten by hand until
a rolling torque is definitely obtained.

ASSEMBLY
17
7
S1 7
s
ne
FIGURE 24: Deviation “H” must be added to a set value of FIGURE 27: Refer and keep to the positions marked during
0.12--0.13 mm (X) to obtain calibrated spacer “S1” (7) for in- disassembly.
sertion between inner bearing (6) and spacer (8).
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EXAMPLE: S1 = H + X = 1,8 + (0.12 - 0.13) = 1,92 - 1,93 mm.
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5 5
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100°
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8
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FIGURE 28: Fit the pinion (5), calibrated spacer “S1” (7) and
6 spacer (8) in the main body (12).
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FIGURE 25: Heat the inner bearing (6) to about 212 °F [100
°C] and fit it onto the pinion (5).
ty
NOTE:
Once the bearing has cooled down, lightly lubricate bea- 5
er
ring (6) with SAE85W90 oil.

op
Pr
FIGURE 29: Heat the external bearing (3) to a temperature of

about 212 °F [100 °C] and fit it on to the pinion (5) to complete
6 the pack as shown in the figure above.
NOTE:
Lightly lubricate bearing (3) with SAE85W90 oil.
FIGURE 26: Make sure that the bearing (6) is well set.

ASSEMBLY
CAUTION
If torque exceeds the maximum value, then the size of cali-
brated spacer “S1” (7) between the bearing (6) and the spa-
cer (8) needs to be increased. If torque does not reach the
set value, increase the torque setting of the ring nut (1) in dif-
ferent stages to obtain a maximum value of 800 - 1000 N·m.
calibrated spacer “S1” (7) needs to be reduced.
5 When calculating the increase or decrease in size of calibra-
terd spacer “S1”, bear in mind that a variation of calibrated
10 spacer (4) of 0.01 mm corresponds to a variation of 60 N·cm
s
in the torque of the pinion (5).
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FIGURE 30: Install the flange (10) onto the pinion (5) without
the sealing ring.
10
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Loctite 242
800 - 1000 N·m
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5
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1
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T1 FIGURE 33: Make positional marks across nut (1) and pinion
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(5) tang; then remove nut and flange (10)

FIGURE 31: Apply wrench to the ring nut (1) and bar-hold T1
(See drawing T1 p. 86) to the pinion (5). Lock the wrench T1
(See drawing T1 p. 86) and rotate the pinion using a torque 12
of
wrench, up to a minimum required torque setting of 800 -

1000 N·m.
ty
120 - 180 N·cm

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9
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T5
FIGURE 34: Apply Arexons rubber cement to the outer surfa-
ce of the new seal ring (9) and fit ring in the main body (12)
using driver T5 (See drawing T5 p. 89).
FIGURE 32: Apply onto the pinion (5) the bar-hold and with
the help of a torque meter, check the torque of the pinion (5).
Torque: 120 - 180 N·cm

ASSEMBLY
s
ne
FIGURE 35: Fit the safety flange (2).
Loctite 242
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1
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10 11
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FIGURE 36: Oil seal ring lips and install flange (10).
Mount o-ring (11) and apply Loctite 242 to pinion tang; tighten
nut (1).
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T1
FIGURE 37: Tighten the nut until the match marks line up.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2308
¯ 185 0.2
0.2
120
80
¯ 105
s
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25 ¯ 105 0.2
125
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10
15
25
125
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ic ¯ 34.5 --+ 00.2
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¯ 50
135 0.5
Am
97
73
61.5
of
61.5
85
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126 12
150
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¯ 32
10
op
15
100
Pr
¯ 45

SPECIAL TOOLS
T2
P/N: 2381
90
¯17
25
131
s
20
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T3
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P/N: 2377
38
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122
8
R 10 5
0.8
R2
25 ic
0 .8
21.5 19.5
0 .8
¯ 104
¯ 109
¯ 55
¯ 69
¯ 85
¯ 89
er
¯ 35
¯ 70
¯ 80
R3
0.8
¯ 19.5
M18 x 1.5
Am
R2
0.8
27 25
28
10 85
30 3 x 15
0.8
of
¯ 35
0.8
450 80 ¯ 25
¯ 19.5
M18 x 1.5
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550
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op
Pr
Cylinder
Thrust block
Thrust block
Differential box

SPECIAL TOOLS
T4
P/N: 2374
¯ 60
30
¯ 6
1/4"
0.8
s
ne
12
70
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0.8
128
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3 x 15
38
an
0.8
M16 x 1.5
ic
20
¯ 20
er
-0.2
¯ 50 -0.4
Am
-0.2
¯ 40 -0.4
0.8
¯ 20
3 x 15
M16 x 1.5
0.8
of
40
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65
67
er
119
¯ 5
163
op
3 x 15
0.8
-0.02
¯ 50 -0.04
37
0.8
Pr
10
44
0.8
A-A
10
¯ 70

SPECIAL TOOLS
T5
P/N: 2375
¯ 50
30
3x45
110
s
158
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195
125
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1 x 45
R5
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28.5
R3
an
6
16.5 +-- 0.0 2
3 x 15
12
0.8
¯ 39.5
ic
0.8
¯ 61.5 + 00.1
er
¯ 85
Am
¯ 98
¯ 125
of
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Pr

SPECIAL TOOLS
s
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LIMITED SLIP DIFFERENTIAL UNIT 45%
EXPLODED VIEW
14
13
12
9
6
11
12
s
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10
13
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14
15
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8
7
5
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4
3
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6
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3
of
1
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DISASSEMBLY
DISASSEMBLY
6
1
7
5
s
2
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FIGURE 4: Remove the upper half box (5) and pull out shims
(6) and clutch pack (7).
FIGURE 1: Remove the whole differential unit (2) from the
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main body (1). (For details, see DIFFERENTIAL UNIT p. 65).
CAUTION
Ai
If the clutch pack does not need replacing, avoid swapping
CAUTION discs position.
an
The following section includes clutch replacement procedu-
res only; for ring gear replacement, see DIFFERENTIAL
UNIT p. 65.
8
ic
er
9
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3
of
FIGURE 5: Remove the planetary gear (8) and planetary gear

ty
set (9).
er
FIGURE 2: Using a puller, remove bearing (3).

op
10
Pr
FIGURE 6: Remove the 2nd planetary gear (10).
FIGURE 3: Make positional match marks on the half boxes of

the differential gear (2); loosen and pull out joining screws (4).

DISASSEMBLY
11
s
ne
FIGURE 7: Remove the 2nd clutch pack (11) and shim set (6).
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CAUTION
Ai
If the clutch pack does not need replacing, avoid swapping
discs position.
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of
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Pr

ASSEMBLY
ASSEMBLY
14
14 12
12 10
88 10
6
6
s
13
13
ne
FIGURE 10: Install planetary gear (10).
FIGURE 8: Only in case of clutch pack replacement: make up
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the packs with increased shims (12), clutch discs (13), inter-
mediate discs (14) and shims (6). 8
Ai
CAUTION 9
an
Add shims (6) until a total size of 17.6 - 0.05 mm is obtained.
ic
11
er
6
Am
FIGURE 11: Fit the planetary gear set (9) and install second
planetary gear (8).
NOTE:
of
Make sure that spherical thrust washers (15) are present.

ty
6
er
FIGURE 9: Fit shims (6) and clutch pack (11) sequentially.

op
CAUTION 7
When installing the increased shim, place shim so that it le-
5
Pr
ans against the ring gear (8, 10).
FIGURE 12: Fit increased shim (12), clutch pack (7) and shims
(6) onto the planetary gear (8).
Fit the upper half box (5) and make sure that the match marks
line up.
Complete the assembling operation and install the differential
unit following the procedures described in the first part of the
manual under section DIFFERENTIAL UNIT p. 65.

SWINGING SUPPORT
EXPLODED VIEW
s
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2
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3
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1
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DISASSEMBLY
DISASSEMBLY
s
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44 Bushing cut position
FIGURE 1: Remove the swinging support (4).
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44
FIGURE 2: Remove the swinging support (4) on the side op-
posite the drive.
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Pr

and remove the complete bushing (3).

ASSEMBLY
ASSEMBLY
A 33
4
4
s
ne
reference direction A FIGURE 6: Install the swinging support (4).
FIGURE 4: If the bushing (3) is worn and needs replacing, wri- NOTE:
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te down the assembly side of the connection notch “A“. Check that it is properly oriented.
Ai
an
ic
er
reference direction A
Am
4
4
FIGURE 7: Install the swinging support (4) on the side oppo-

of
site the drive.

ty
er
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Pr
4
4

and insert the complete bushing (3).

s
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Pr

COPIES.
Service Parts List
es
Axle
123/182
n
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APL-2520
September 2012
SPICER OFF-HIGHWAY AXLE DIVISION *123/182* 2139585432
Data rilascio
13/03/2012
N° foglio
1
Denominazione Gruppo tipo Modello Cliente: TUG TECHNOLOGIES C.I. e data
Ponte differenziale fisso con riduzioni finali epicicloidali 123 182 ultima
Cod.cliente: 180107 N° disegno 123.97.000.182 modifica
Quantità olio Macchina: TRATTORE AEREOPORTUALE GT35 R 0562
Note 13/03/2012
ATTENZIONE:
s
- I gruppi vanno spediti riempiti di olio
ne
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Ai
Flangia a flangia [mm] 1920.
Rapporto coppia conica 8:31
Rapporto riduzioni finali 1:6 - 3 sat. Int.col. 335
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Denominazione Sottogruppo Caratteristiche N°Complessivo
Scatola e 123-01/02 123.01.000.02

coperchi of
Differenziale 123-04/30 Autobloccante 45% 123.04.000.01
Mozzo ruota 123-06/05 Colonnette M22 L=76 - Dadi piani 123.06.000.02

ty
Flangia MECHANICS 6C
Freno 123-07/09 A disco in bagno d'olio 6 dischi Wellman - Gioco 1 mm 123.07.000.04
er
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Particolari sciolti
Pr
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ne
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123-01-0001
123/182 1
CENTRAL HOUSING 21/09/12
123 123-01/02
1 001.05.3471 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
es
2 112.01.018.02 1 TAPPO SFIATO
RENIFLARD
VENT
n
TAPÓN DE RESPIRADERO
ENTLUEFTER
rli
3 123.01.007.03 1 COPERCHIO INTERMEDIO
Ai
COUVERCLE INTERMEDIAIRE
INTERMEDIATE COVER
TAPA DE INTERMEDIO
4 176.07.029.01 1 ANELLO OR
an
ZWISCHENDECKEL
ic
JOINT OR
O - RING
er
ANILLO TOROIDAL
O - RING
Am
5 016.04.1121 4 VITE
VIS
BOLT
TORNILLO
of
SCHRAUBE
6 355.14.610.02 1 TAPPO
ty
BOUCHON
PLUG
er
TAPÓN
STOPFEN
op
7 171.01.015.04 1 TAPPO
BOUCHON
PLUG
Pr
TAPÓN
STOPFEN
8 002.02.0088 1 ANELLO DI SICUREZZA
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
123-01-0001
123/182 2
123 123-01/02
9 355.14.611.02 1 TAPPO MAGNETICO
BOUCHON MAGNETIQUE
MAGNET PLUG
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
es
10 123.01.001.01 1 SCATOLA
CARTER
HOUSING
n
CAJA
GEHAEUSE
rli
Ai
an
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Am
of
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er
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Pr
2012-08-20
Pr
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of
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ne
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123-04-0002
123/182 1
DIFFERENTIAL 21/09/12
123 123-04/30
1 016.30.4162 2 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
es
2 194.04.001.01 2 GHIERA
ECROU
RING NUT
n
ABRAZADERA
WELLENMUTTER
rli
3 005.09.0762 2 CUSCINETTO A RULLI CONICI
Ai
ROULEMENT A R. CONIQUES
TAPER ROLLER BEARING
COJINETE DE BOLAS
4 016.28.3390 16 VITE
an
KEGELROLLENLAGER
ic
VIS
BOLT
er
TORNILLO
SCHRAUBE
Am
5 123.04.704.01 1 SCATOLA DIFFERENZIALE

CARTER DIFFERENTIEL
DIFFERENTIAL CARRIER
CAJA DE DIFERENCIAL
of
DIFFERENTIALGEHAEUSE
6 176.04.504.09 1 COPPIA CONICA
ty
COUPLE CONIQUE
BEVEL GEAR SET
er
PAR CONICO
KEGEL- UND TELLERRADPAAR
op
7
Pr
8 113.04.045.01 2 PLANETARIO
PLANETAIRE
DIFFERENTIAL SIDE GEAR
PLANETARIO
AUSGLEICHSWELLENRAD
9 139.04.001.01 4 RONDELLA DI RASAMENTO
RONDELLE
FRICTION WASHER
ARANDELA DE FRICCIÓN
123-04-0002
123/182 2
123 123-04/30
ANLAUFSCHEIBE
10 113.04.043.01 4 SATELLITE
SATELLITE
DIFFERENTIAL PINION
ENGRANAJE SATÉLITE
es
AUSGLEICHSKEGELRAD
11 139.04.002.02 2 PERNO DIFFERENZIALE
n
AXE
DIFFERENTIAL SHAFT
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PERNO DE DIFERENCIAL
AUSGLEICHSBOLZEN
Ai
12 016.38.4239 15 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
an
ic
er
Am
COJINETE DE BOLAS
KEGELROLLENLAGER
14 113.04.400.07 1 KIT ANELLI
KIT ARRETOIR
of
RING KIT
KIT DE ANILLO
RINGE KIT
ty
15 113.04.048.01 1 DISTANZIALE
er
ENTRETOISE
SPACER
DISTANCIADOR
op
DISTANZRING
16 001.13.1234 1 ANELLO DI TENUTA
Pr
JOINT D'ETANCHEITE
SEAL
ANILLO DE ESTANQUEIDAD
DICHTRING
17 001.05.0818 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
123-04-0002
123/182 3
123 123-04/30
18 734.04.035.01 1 DADO
ECROU
NUT
TUERCA
MUTTER
es
19 276.01.005.01 1 LAMIERA DI PROTEZIONE
PROTECTION EN TOLE
COVER PLATE
n
CHAPA DE PROTECCIÓN
SCHUTZBLECH
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Ai
COJINETE DE BOLAS
21 123.04.400.03 1
KEGELROLLENLAGER
KIT SPESSORI
an
ic
KIT CALES
SHIM KIT
er
KIT DE ESPESOR
PASS-SCHEIBEN KIT
Am
22
of
23 734.04.073.02 1 FLANGIA
BRIDE
ty
FLANGE
BRIDA
er
FLANSCH
24 123.04.756.02 1 DIFFERENZIALE
op
DIFFERENTIEL
DIFFERENTIAL
DIFERENCIAL
Pr
DIFFERENTIAL
25
26
123-04-0002
123/182 4
123 123-04/30
27
28
nes
29
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30
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31
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32
of
33
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34
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Pr
35
36
37
123-04-0002
123/182 5
123 123-04/30
38
39
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40
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41
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42
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44 113.04.610.01 2 DISCO FRIZIONE

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DISQUE D'EMBRAJAGE
CLUTCH DISC
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DISCO DE EMBRAGUE
KUPPLUNGSSCHEIBE
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Pr
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123-06-0001
123/182 1
HUB REDUCTION 21/09/12
123 123-06/05
1 123.06.013.13 2 BRACCIO
CORPS D'ESSIEU
AXLE CASE
BRAZO
ACHSKOERPER
es
2
n
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3 112.06.070.06 32 VITE A TESTA ESAGONALE
VIS A TETE EXAGONALE
Ai
HEXAGON BOLT
TORNILLO DE CABEZA HEXAGONAL
SECHSKANTSCHRAUBE
4 123.06.022.01 2 SEMIASSE
DEMI-ARBRE
an
ic
HALF SHAFT
SEMIEJE
er
ACHSWELLE
Am

JOINT D'ETANCHEITE
SEAL
DICHTRING
of
6 113.06.019.01 2 ANELLO
BAGUE
ty
RING
ANILLO
er
RING
7 123.06.016.01 2 ANELLO DI TENUTA
op
JOINT D'ETANCHEITE
SEAL
Pr
DICHTRING
COJINETE DE BOLAS
KEGELROLLENLAGER
9 932.06.074.01 20 COLONNETTA
GOUJON DE ROUE
WHEEL STUD
PRISIONERO
123-06-0001
123/182 2
123 123-06/05
RADBOLZEN
10 123.06.009.02 2 MOZZO RUOTA
MOYEU DE ROUE
WHEEL HUB
CUBO DE MAZA
es
RADNABE
11 112.06.088.03 20 DADO
n
ECROU
NUT
rli
TUERCA
MUTTER
Ai
12 176.07.029.01 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
an
ic
13 002.14.3202 6 ANELLO D'ARRESTO
er
BAGUE D'ARRET
SNAP RING
Am
ARO DE RETENCIÓN
SPRENGRING
14 290.06.011.02 6 SATELLITE (PLAN.)
SATELLITE
of
PLANET GEAR
ENGRANAJE PLANETARIO
PLANETENRAD
ty
15 290.06.013.03 6 CUSCINETTO
er
ROULEMENT
BEARING
COJINETE
op
LAGER
16 123.06.710.05 2 SUPPORTO SATELLITI
Pr
SUPPORT SATELLITES
PLANET GEAR CARRIER
TAPA PORTASATÉLITES
PLANETENGEHAEUSE
SUPPORT SATELLITES
PLANET GEAR CARRIER
PLANETENGEHAEUSE
123-06-0001
123/182 3
123 123-06/05
18 355.14.610.02 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
es
19 016.06.0442 4 VITE A TESTA CONICA
VIS A TETE CONIQUE
COUNTERSUNK BOLT
n
TORNILLO DE CABEZA CONICA
SENKSCHRAUBE
rli
Ai
RONDELLE
FRICTION WASHER
21 006.22.4177 16
ANLAUFSCHEIBE
DADO
an
ic
ECROU
NUT
er
TUERCA
MUTTER
Am
22 176.06.065.02 16 PRIGIONIERO
GOUJON
STUD
PRISIONERO
of
STIFTSCHRAUBE
23 113.06.007.01 2 LAMIERA DI SICUREZZA
ty
TOLE DE SECURITE
LOCKING PLATE
er
BLOQUEO DE LA CUBIERTA
SICHERUNGSBLECH
op
24 113.06.008.01 2 SUPPORTO PORTACORONA

SUPPORT PORTE COURONNE
RING GEAR SUPPORT
Pr
SOPORTE DE CORONA
HOHLRADTRAEGER
25 290.06.010.07 2 CORONA DENTATA
COURONNE DENTEE
RING GEAR
CORONA DENTADA
ZAHNKRANZ
123-06-0001
123/182 4
123 123-06/05
26 290.06.014.02 2 ANELLO DI SICUREZZA
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
es
BOUCHON MAGNETIQUE
MAGNET PLUG
n
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
rli
28
Ai
29
an
ic
er
30
Am
31
of
ty
32
er
op

Pr
RING GEAR SUPPORT

SOPORTE DE CORONA
HOHLRADTRAEGER
2012-08-14
s
ne
rli
Ai
an
ic
er
Am
19
of
ty
er
op
Pr
16 KIT = 17+19
123-07-0004
123/182 1
BRAKES 21/09/12
123 123-07/09
1 123.07.016.01 2 ANELLO ANTIESTRUSIONE
BAGUE ANTIEXTRUSION
BACK - UP RING
ANILLO ANTIEXTRUSIÓN
ANTIEXTRUSIONSRING
es
2 001.05.3736 2 ANELLO OR
JOINT OR
O - RING
n
ANILLO TOROIDAL
O - RING
rli
Ai
BAGUE ANTIEXTRUSION
BACK - UP RING
4 001.05.1251 2 ANELLO OR
an
ANTIEXTRUSIONSRING
ic
JOINT OR
O - RING
er
ANILLO TOROIDAL
O - RING
Am
5 123.07.010.05 2 PISTONE
PISTON
PISTON
PISTÓN
of
KOLBEN
6 112.07.002.03 6 MOLLA
ty
RESSORT
SPRING
er
MUELLE
FEDER
op
7 112.07.037.09 6 VITE REGISTRO

VIS DE REGLAGE
ADJUSTING BOLT
Pr
TORNILLO EN REGISTRO
NACHSTELLSCHRAUBE
8 171.07.010.02 6 MOLLA
RESSORT
SPRING
MUELLE
FEDER
123-07-0004
123/182 2
BRAKES 21/09/12
123 123-07/09
9 154.06.014.02 6 VITE REGISTRO
VIS DE REGLAGE
ADJUSTING BOLT
NACHSTELLSCHRAUBE
es
10 154.07.001.01 6 DISCO FRENO INTERMEDIO
DISQUE INTERMEDIAIRE
INTERMEDIATE BRAKE DISC
n
DISCO DE FRENO INTERMEDIO
GEGENLAMELLE
rli
11 113.07.610.01 6 DISCO FRENO
Ai
DISQUE DE FREIN
BRAKE DISC
DISCO DE FRENO
12 113.07.014.02 2
BREMSSCHEIBE
BUSSOLA
an
ic
MANCHON DE REDUCTION
REDUCTION BUSHING
er
CASQUILLO
ZWISCHENBUCHSE
Am
13 123.07.011.02 2 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
of
DISTANZRING
14 734.07.014.01 2 VITE SPURGO
ty
VIS DE PURGE
BLEEDING BOLT
er
PURGADOR
ABBLASESCHRAUBE
op
15 734.07.015.01 2 TAPPO
BOUCHON
PLUG
Pr
TAPÓN
STOPFEN
16 112.07.615.01 2 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
123-07-0004
123/182 3
BRAKES 21/09/12
123 123-07/09
17 011.07.4225 2 ROSETTA DI TENUTA
BAGUE D'ETANCHEITE
SEAL WASHER
ARANDELA DE ESTANQUIDAD
DICHTRING
es
18 162.07.004.05 2 VITE SPINA
VIS A BROCHE
PILOT BOLT
n
TORNILLO DE ENCHUFE
FUEHRUNGSSCHRAUBE
rli
19 016.10.4218 2 VITE DI CHIUSURA
Ai
VIS DE FERMETURE
PLUG
TAPÓN
an
VERSCHLUSS-SCHRAUBE
ic
er
Am
of
ty
er
op
Pr
Pr
op
er
ty
of
Am
er
ic
an
Ai
rli
nes
nes
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

COPIES.
Service Parts List
es
Axle
223/103
n
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
APL-2519
September 2012
SPICER OFF-HIGHWAY AXLE DIVISION *223/103* 2139585434
Data rilascio
13/03/2012
N° foglio
1
Denominazione Gruppo tipo Modello Cliente: TUG TECHNOLOGIES C.I. e data
Ponte differenziale sterzante con riduzioni finali epicicloidali 223 103 ultima
Cod.cliente: 180107 N° disegno 223.97.000.103 modifica
Quantità olio Macchina: TRATTORE AEREOPORTUALE GT35 R 0562
Note 13/03/2012
ATTENZIONE:
s
- I gruppi vanno spediti riempiti di olio
ne
rli
Ai
Flangia a flangia [mm] 1920.
Rapporto coppia conica 8:31
Rapporto riduzioni finali 1:6 - 3 sat. Int. col. 335
an
Sterzatura [gradi] 30
ic
er
Am
Denominazione Sottogruppo Caratteristiche N°Complessivo
Scatola e 223-01/10 223.01.000.01

coperchi of
Differenziale 223-04/11 Autobloccante 45% 123.04.000.01
Flangia Mechanics 6C
Mozzo ruota 223-06/33 Colonnette M22 L=76 - Dadi piani 223.06.000.04
ty
Freno 123-07/09 A disco in bagno d'olio 6 dischi Wellman - Gioco 1 mm 123.07.000.03

er
Cilindro sterzo 223-24/02 Cilindro 180 BAR - Senza sensore - Alim. 45° dietro - 3/4" 223.24.000.01
op
16UNF - Corsa 135

Supporti 223-25/02
oscillanti
Pr
Proteggere dalla verniciatura

Particolari sciolti
Montare il tappo sfiato sul braccio lato corona conica

Pr
op
er
ty
of
Am
er
ic
an
Ai
rli
ne
s
223-01-0001
223/103 1
223 223-01/10
1 112.01.018.02 1 TAPPO SFIATO
RENIFLARD
VENT
TAPÓN DE RESPIRADERO
ENTLUEFTER
es
2 123.01.007.03 1 COPERCHIO INTERMEDIO
COUVERCLE INTERMEDIAIRE
INTERMEDIATE COVER
n
TAPA DE INTERMEDIO
ZWISCHENDECKEL
rli
3 176.07.029.01 1 ANELLO OR
Ai
JOINT OR
O - RING
ANILLO TOROIDAL
4 002.02.0088 1
O - RING an
ANELLO DI SICUREZZA
ic
ARRETOIR
CIRCLIP
er
ANILLO DE SEGURIDAD
SICHERUNGSRING
Am
5 171.01.015.04 1 TAPPO
BOUCHON
PLUG
TAPÓN
of
STOPFEN
6 355.14.610.02 1 TAPPO
ty
BOUCHON
PLUG
er
TAPÓN
STOPFEN
op

BOUCHON MAGNETIQUE
MAGNET PLUG
Pr
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
8 223.01.008.01 1 SCATOLA
CARTER
HOUSING
CAJA
GEHAEUSE
223-01-0001
223/103 2
223 223-01/10
9 016.04.1121 4 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
es
10 001.05.3471 2 ANELLO OR
JOINT OR
O - RING
n
ANILLO TOROIDAL
O - RING
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
2012-08-16
10
Pr
op
er
ty
of
Am
er
ic
an
Ai
rli
ne
s
223-04-0001
223/103 1
223 223-04/11
1 734.04.035.01 1 DADO
ECROU
NUT
TUERCA
MUTTER
es
2 276.01.005.01 1 LAMIERA DI PROTEZIONE
PROTECTION EN TOLE
COVER PLATE
n
CHAPA DE PROTECCIÓN
SCHUTZBLECH
rli
Ai
COJINETE DE BOLAS
4 123.04.400.03 1
KEGELROLLENLAGER
KIT SPESSORI
an
ic
KIT CALES
SHIM KIT
er
KIT DE ESPESOR
PASS-SCHEIBEN KIT
Am
5 176.04.504.09 1 COPPIA CONICA

COUPLE CONIQUE
BEVEL GEAR SET
PAR CONICO
of
KEGEL- UND TELLERRADPAAR

ty
er
COJINETE DE BOLAS
KEGELROLLENLAGER
op
7 113.04.400.07 1 KIT ANELLI

KIT ARRETOIR
RING KIT
Pr
KIT DE ANILLO
RINGE KIT
8 113.04.048.01 1 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
DISTANZRING
223-04-0001
223/103 2
223 223-04/11
JOINT D'ETANCHEITE
SEAL
DICHTRING
es
10 734.04.073.02 1 FLANGIA
BRIDE
FLANGE
n
BRIDA
FLANSCH
rli
11 001.05.0818 1 ANELLO OR
Ai
JOINT OR
O - RING
ANILLO TOROIDAL
12 005.09.0762 2
O - RING an
CUSCINETTO A RULLI CONICI
ic
er
COJINETE DE BOLAS
KEGELROLLENLAGER
Am
13 194.04.001.01 2 GHIERA
ECROU
RING NUT
ABRAZADERA
of
WELLENMUTTER
14 016.30.4162 2 VITE
ty
VIS
BOLT
er
TORNILLO
SCHRAUBE
op
15 016.28.3390 16 VITE
VIS
BOLT
Pr
TORNILLO
SCHRAUBE
16 123.04.704.01 1 SCATOLA DIFFERENZIALE
CARTER DIFFERENTIEL
DIFFERENTIAL CARRIER
CAJA DE DIFERENCIAL
DIFFERENTIALGEHAEUSE
223-04-0001
223/103 3
223 223-04/11
17
18 113.04.610.01 2 DISCO FRIZIONE
es
DISQUE D'EMBRAJAGE
CLUTCH DISC
DISCO DE EMBRAGUE
n
KUPPLUNGSSCHEIBE
rli
19
Ai
20 113.04.045.01 2 PLANETARIO
PLANETAIRE
an
DIFFERENTIAL SIDE GEAR
ic
PLANETARIO
AUSGLEICHSWELLENRAD
er

Am
RONDELLE
FRICTION WASHER
ANLAUFSCHEIBE
of
22 113.04.043.01 4 SATELLITE
SATELLITE
DIFFERENTIAL PINION
ty
ENGRANAJE SATÉLITE
AUSGLEICHSKEGELRAD
er
23 139.04.002.02 2 PERNO DIFFERENZIALE

AXE
op
DIFFERENTIAL SHAFT
PERNO DE DIFERENCIAL
AUSGLEICHSBOLZEN
Pr
24 016.38.4239 15 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
25
223-04-0001
223/103 4
223 223-04/11
26 123.04.756.02 1 DIFFERENZIALE
DIFFERENTIEL
DIFFERENTIAL
DIFERENCIAL
DIFFERENTIAL
es
n
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr
2012-09-21
69
69
s
ne
rli
Ai
an
ic
er
Am
35
of
ty
52 KIT = 36+37+38+40+41+42+43 50
er
62 KIT = 15+28
op
63 KIT = 15+29 66 KIT = 36+37+38 52

Pr
64 KIT = 26+27 70 KIT = 40+41+42+43

223-06-0001
223/103 1
223 223-06/33
1 223.06.027.01 2 BRACCIO
CORPS D'ESSIEU
AXLE CASE
BRAZO
ACHSKOERPER
es
2 016.13.3271 2 VITE
VIS
BOLT
n
TORNILLO
SCHRAUBE
rli
3 006.03.0197 2 DADO
Ai
ECROU
NUT
TUERCA
4
MUTTER an
ic
er
Am
5
of
6 112.06.070.14 32 VITE A TESTA ESAGONALE

VIS A TETE EXAGONALE
HEXAGON BOLT
ty
TORNILLO DE CABEZA HEXAGONAL

SECHSKANTSCHRAUBE
er

ARRETOIR
op
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
Pr

ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
9 005.01.0121 2 CUSCINETTO A SFERE
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
223-06-0001
223/103 2
223 223-06/33
JOINT D'ETANCHEITE
SEAL
DICHTRING
es
11 001.05.1389 2 ANELLO OR
JOINT OR
O - RING
n
ANILLO TOROIDAL
O - RING
rli
12 212.06.700.01 2 BUSSOLA
Ai
REDUCTION BUSHING
CASQUILLO
13 223.06.613.14 2
an
ZWISCHENBUCHSE
DOPPIO GIUNTO CARDANICO
ic
DOUBLE JOINT CARDAN
DOUBLE UNIVERSAL JOINT
er
JUNTA CARDAN DE DOBLE CRUCETA

KARDAN-DOPPELGELENKWELLE
Am

JOINT D'ETANCHEITE
SEAL
of
DICHTRING
15 290.06.020.03 1 BRONZINA
ty
1 DOUILLE
THRUST BUSHING
er
BUJE
ANLAUFBUCHSE
op
16 016.28.3390 24 VITE
VIS
BOLT
Pr
TORNILLO
SCHRAUBE
17
18 008.01.0213 2 INGRASSATORE
2 GRAISSEUR
GREASE FITTING
ENGRASADOR
223-06-0001
223/103 3
223 223-06/33
KEGEL - SCHMIERNIPPEL
19 223.06.702.01 2 PERNO SNODO
PIVOT DE DIRECTION
PIVOT PIN
PERNO DE DIRECCIÓN
es
ACHSSCHENKELBOLZEN
20 212.06.400.48 1 KIT SPESSORI
n
KIT CALES
SHIM KIT
rli
KIT DE ESPESOR
PASS-SCHEIBEN KIT
Ai
21 213.06.006.03 2 ANELLO PARAPOLVERE
2 BAGUE ANTI-POUSSIERE
DUST EXCLUDERan
ANILLO DE POLVO
STAUBABWEHRRING
ic
22
er
Am
23 212.06.023.03 2 BOCCOLA
DOUILLE
BUSHING
of
CASQUILLO GUÍA
BUCHSE
ty
24 290.06.016.01 2 CUSCINETTO
ROULEMENT
er
BEARING
COJINETE
LAGER
op
25 223.06.701.02 2 PERNO SNODO

PIVOT DE DIRECTION
Pr
PIVOT PIN
PERNO DE DIRECCIÓN
ACHSSCHENKELBOLZEN
26 006.05.1521 4 DADO
ECROU
NUT
TUERCA
MUTTER
223-06-0001
223/103 4
223 223-06/33
27 213.06.011.01 4 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
es
28 223.06.019.01 1 SCATOLA SNODO
BOITIER DE DIRECTION
STEERING CASE
n
EJE DE ARTICULACIÓN
GELENKGEHAEUSE
rli
29 223.06.020.01 1 SCATOLA SNODO
Ai
STEERING CASE
30 355.14.611.02 2
GELENKGEHAEUSE
TAPPO MAGNETICO
an
ic
BOUCHON MAGNETIQUE
MAGNET PLUG
er
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
Am
31 355.14.610.02 2 TAPPO
BOUCHON
PLUG
TAPÓN
of
STOPFEN
32
ty
er

op
JOINT D'ETANCHEITE
SEAL
Pr
DICHTRING
COJINETE DE BOLAS
KEGELROLLENLAGER
35 213.06.004.01 2 MOZZO RUOTA
MOYEU DE ROUE
WHEEL HUB
CUBO DE MAZA
223-06-0001
223/103 5
223 223-06/33
RADNABE
36 290.06.014.02 2 ANELLO DI SICUREZZA
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
es
SICHERUNGSRING
37 290.06.010.07 2 CORONA DENTATA
n
COURONNE DENTEE
RING GEAR
rli
CORONA DENTADA
ZAHNKRANZ
Ai
an
RING GEAR SUPPORT
SOPORTE DE CORONA
HOHLRADTRAEGER
ic
39 113.06.007.01 2 LAMIERA DI SICUREZZA
er
TOLE DE SECURITE
LOCKING PLATE
Am
BLOQUEO DE LA CUBIERTA
SICHERUNGSBLECH
40 002.14.3202 6 ANELLO D'ARRESTO
BAGUE D'ARRET
of
SNAP RING
ARO DE RETENCIÓN
SPRENGRING
ty
41 290.06.011.02 6 SATELLITE (PLAN.)

er
SATELLITE
PLANET GEAR
ENGRANAJE PLANETARIO
op
PLANETENRAD
42 290.06.013.03 6 CUSCINETTO
Pr
ROULEMENT
BEARING
COJINETE
LAGER
SUPPORT SATELLITES
PLANET GEAR CARRIER
PLANETENGEHAEUSE
223-06-0001
223/103 6
223 223-06/33
44
45 112.01.610.01 2 TAPPO
es
BOUCHON
PLUG
TAPÓN
n
STOPFEN
rli
46 016.06.0442 4 VITE A TESTA CONICA
VIS A TETE CONIQUE
Ai
COUNTERSUNK BOLT
TORNILLO DE CABEZA CONICA
SENKSCHRAUBE
47 006.22.4177 16 DADO
ECROU
an
ic
NUT
TUERCA
er
MUTTER
Am
48 176.06.065.02 16 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
of
49 001.05.1119 2 ANELLO OR
JOINT OR
ty
O - RING
ANILLO TOROIDAL
er
O - RING
50 112.06.088.03 20 DADO
op
ECROU
NUT
TUERCA
Pr
MUTTER
51 932.06.074.01 20 COLONNETTA
GOUJON DE ROUE
WHEEL STUD
PRISIONERO
RADBOLZEN
SUPPORT SATELLITES
PLANET GEAR CARRIER
223-06-0001
223/103 7
223 223-06/33
PLANETENGEHAEUSE
53
es
54
n
rli
55
Ai
56
an
ic
er
57
Am
58
of
ty
59
er
op
60
Pr
61
62 223.06.719.01 1 SCATOLA SNODO

STEERING CASE
223-06-0001
223/103 8
223 223-06/33
GELENKGEHAEUSE
63 223.06.720.01 1 SCATOLA SNODO
STEERING CASE
es
GELENKGEHAEUSE
64 213.06.711.01 4 VITE DI FERMO STERZO
n
VIS D'ARRET BRAQUAGE
STEERING ADJUST BOLT
rli
TORNILLO DE TOPE DE DIRECCIÓN
LENKEINSCHLAGSCHRAUBE
Ai
65
an
ic
er
RING GEAR SUPPORT

SOPORTE DE CORONA
Am
HOHLRADTRAEGER
67
of
68
ty
er

op
VIS DE FERMETURE
PLUG
TAPÓN
Pr
VERSCHLUSS-SCHRAUBE
SUPPORT SATELLITES
PLANET GEAR CARRIER
PLANETENGEHAEUSE
2012-08-14
s
ne
rli
Ai
an
ic
er
Am
19
of
ty
er
op
Pr
16 KIT = 17+19
123-07-0004
223/103 1
BRAKES 21/09/12
123 123-07/09
BAGUE ANTIEXTRUSION
BACK - UP RING
ANTIEXTRUSIONSRING
es
2 001.05.3736 2 ANELLO OR
JOINT OR
O - RING
n
ANILLO TOROIDAL
O - RING
rli
Ai
BAGUE ANTIEXTRUSION
BACK - UP RING
4 001.05.1251 2 ANELLO OR
an
ANTIEXTRUSIONSRING
ic
JOINT OR
O - RING
er
ANILLO TOROIDAL
O - RING
Am
5 123.07.010.05 2 PISTONE
PISTON
PISTON
PISTÓN
of
KOLBEN
6 112.07.002.03 6 MOLLA
ty
RESSORT
SPRING
er
MUELLE
FEDER
op
7 112.07.037.09 6 VITE REGISTRO

VIS DE REGLAGE
ADJUSTING BOLT
Pr
NACHSTELLSCHRAUBE
8 171.07.010.02 6 MOLLA
RESSORT
SPRING
MUELLE
FEDER
123-07-0004
223/103 2
BRAKES 21/09/12
123 123-07/09
9 154.06.014.02 6 VITE REGISTRO
VIS DE REGLAGE
ADJUSTING BOLT
NACHSTELLSCHRAUBE
es
10 154.07.001.01 6 DISCO FRENO INTERMEDIO
DISQUE INTERMEDIAIRE
INTERMEDIATE BRAKE DISC
n
DISCO DE FRENO INTERMEDIO
GEGENLAMELLE
rli
11 113.07.610.01 6 DISCO FRENO
Ai
DISQUE DE FREIN
BRAKE DISC
DISCO DE FRENO
12 113.07.014.02 2
BREMSSCHEIBE
BUSSOLA
an
ic
REDUCTION BUSHING
er
CASQUILLO
ZWISCHENBUCHSE
Am
13 123.07.011.02 2 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
of
DISTANZRING
14 734.07.014.01 2 VITE SPURGO
ty
VIS DE PURGE
BLEEDING BOLT
er
PURGADOR
ABBLASESCHRAUBE
op
15 734.07.015.01 2 TAPPO
BOUCHON
PLUG
Pr
TAPÓN
STOPFEN
16 112.07.615.01 2 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
123-07-0004
223/103 3
BRAKES 21/09/12
123 123-07/09
17 011.07.4225 2 ROSETTA DI TENUTA
BAGUE D'ETANCHEITE
SEAL WASHER
ARANDELA DE ESTANQUIDAD
DICHTRING
es
18 162.07.004.05 2 VITE SPINA
VIS A BROCHE
PILOT BOLT
n
TORNILLO DE ENCHUFE
FUEHRUNGSSCHRAUBE
rli
Ai
VIS DE FERMETURE
PLUG
TAPÓN
an
VERSCHLUSS-SCHRAUBE
ic
er
Am
of
ty
er
op
Pr
Pr
op
er
ty
of
Am
er
ic
an
Ai
rli
ne
s
223-24-0001
223/103 1
STEERING 21/09/12
223 223-24/02
1 213.24.620.06 1 CILINDRO
CILINDRE
CYLINDER
CILINDRO
ZYLINDER
es
2 001.05.1629 2 ANELLO OR
JOINT OR
O - RING
n
ANILLO TOROIDAL
O - RING
rli
3 213.24.621.23 2 ASTA
Ai
TIGE
BAR
VARILLA
4 016.30.4244 5
STANGE
VITE
an
ic
VIS
BOLT
er
TORNILLO
SCHRAUBE
Am
of
ty
er
op
Pr
Pr
op
er
ty
of
Am
er
ic
an
Ai
rli
ne
s
223-25-0001
223/103 1
TRUNION 21/09/12
223 223-25/02
1 276.25.002.02 4 BUSSOLA
BUSHING
CASQUILLO
BUCHSE
es
2 276.25.003.01 2 BRONZINA
DOUILLE
THRUST BUSHING
n
BUJE
ANLAUFBUCHSE
rli
3 213.25.007.01 2 SUPPORTO
Ai
SUPPORT
SUPPORT
SOPORTE
4 008.01.0213 2
HALTERUNG
INGRASSATORE
an
ic
GRAISSEUR
GREASE FITTING
er
ENGRASADOR
KEGEL - SCHMIERNIPPEL
Am
5 734.07.015.01 2 TAPPO
BOUCHON
PLUG
TAPÓN
of
STOPFEN
6 213.25.612.01 2 SUPPORTO
ty
SUPPORT
SUPPORT
er
SOPORTE
HALTERUNG
op
Pr
nes
rli
Ai
an
ic
er
Am
of
ty
er
op
Pr

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Spicer Axle 123

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Service Manual

SPECIAL TOOLS .............................................................................................................................................................. 33

DIFFERENTIAL UNIT ........................................................................................................................ 37

EXPLODED VIEW ............................................................................................................................................................. 49

SPECIAL TOOLS .............................................................................................................................................................. 58

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 3

4 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

directly from the Service Centers or Authorized Distributors of SPICER.

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 5

38062 Arco (Trento)

1 - Type and model unit - modification index

6 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

1N 1 0,1 0,001 0,102 0,225

1kN 1000 100 1 102 225

1daN·m 10 1 0,01 1,02 88,54

1kg·m 9,81 0,981 0,00981 1 86,8

1 lb·in 0,1129 0,01129

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 7

SIZE OF BOLT TYPE OF BOLT

SIZE OF BOLT TYPE OF BOLT

8 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

WHEEL NUT TIGHTENING TORQUES

RECOMMENDED WHEEL NUTS TORQUE

CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY

M18 x 1,5 mm 330 N·m 460 N·m

M18 x 1,5 mm 260 N·m 360 N·m

DANA OFFICIAL TIGHTENING TORQUE TABLE

M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m

M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m

M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 9

1 - Oil filling plug

3 - Check level plug

For details see BRAKE WEAR CHECK PROCEDURE p. 15

10 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

OPERATION FREQUENCY LUBRICANTS

Differential Monthly SAE85W90 (API GL4 - MIL L-2105)

Differential Every 800 hrs * SAE85W90 (API GL5 - MIL 2105-B)

If working in severe duty conditions half intervals should be used

Normal work Monthly

UNIT OPERATION FREQUENCY

Negative brake Adjustment Every 1000 hours*

Wheel nuts Tightening Every 200 hours**

* Initially after 100 working hours

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 11

LUBRICANT & SEALANT SPECIFICATIONS

AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS)

TECNO LUBE/101 (SILICONE-BASED GREASE)

12 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 13

14 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

FIGURE 2: Apply the parking brake (or have someone hold

stance between discs using tool T1 (See drawing T1 p. 17).

Replace the braking disks and the intermediate disks on

FIGURE 3: Checking brake distance with the T1 go / no-go

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 15

FIGURE 2: Apply the parking brake (or have someone hold

stance between discs using tool T1 (See drawing T1 p. 17).

Replace the braking disks and the intermediate disks on

both sides if necessary. See SERVICE BRAKE p. 19.

FIGURE 3: Checking brake distance with the T1 go / no-go

16 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual

ASM-0007E - 123 Axle Service Manual Dana Holding Corporation 17

18 Dana Holding Corporation ASM-0007E - 123 Axle Service Manual