MAHINDRA 

SPECIAL TOOL MANUAL 
 

mEagle
 
MAN-00051
Rev 1

914xxxR010109EN-SM

         
 

     

                                                                                                       

RELEASED BY -

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com  Rev1 – JANUARY 2009

All information contained in this manual is most up-to-date at the time of publication. However, specifications and procedures
are subject to change without notice. This manual is strictly meant for restricted internal circulation within M&M Authorized
dealer service centers.

© 2009 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without 
the written permission of Mahindra & Mahindra Ltd. 

 
ABOUT THE MAHINDRA SPECIAL TOOL (MST) MANUAL

The Special Tool manual outlines the detailed procedures on the usage and application of Mahindra Special
Tools (MST) on XYLO mEagle vehicle. Special tools are designed to carry out specialized repair
operations requiring high level of accuracy & control, which cannot be achieved using the normal workshop
tools and equipments. Special tools are also designed carry out repair operations in locations which are not
accessible by normal tools.

The manual covers the usage instructions for each tool , giving the sketch of the tool as well as a photo of
the intended operation it is supposed to perform.
Special Tool No 

Special Tool Description 

Location of  use 

Photo of Tool 

Description of Operation 

Usage of the tool 

In spite of our best efforts to make the manual error-free, a few errors could have inadvertently crept in. If
you identify errors, functional or typographical , please inform your TEKline or pillay.ajay@mahindra.com.
Suggestions to improve the manual and make it more user-friendly are also welcome.

© 2009 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without 
the written permission of Mahindra & Mahindra Ltd. 

 
 Special Tool Manual MAN-00051-1 
Xylo mEagle Jan 2009/Rev 1  
 

0401BAA0003ST LOWER ARM TOOL KIT-XYLO Front Suspension

 
OPERATION -
 

 
1. Arrange the Tools as illustrated in the
  operation photo below.
2. Install on Press.
  3. Rotate the press handle to Drive out
the bush
 

 
# 
 
# Dummy Plug to be used at an empty Eye
  while extracting other bush.

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-2 
Xylo mEagle Jan 2009/Rev 1  
 

0401BAA0004ST UPPER ARM TOOL KIT-XYLO Front Suspension

 
OPERATION -
 

  1. Arrange the Tools as illustrated in the

operation photo below.
#    2. Install on Press.
3. Rotate the press handle to Drive out
  the bush
 

  # Dummy Plug to be used at an empty Eye

while extracting other bush.
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-3 
Xylo mEagle Jan 2009/Rev 1  
 

0401BAA0005ST SUSPENSION TOOL FIXTURE -XYLO Front Suspension

  OPERATION -

  1. Arrange the Tools as illustrated in the

operation photo below.
  2. Install on Press.
3. Rotate the press handle to Drive out
  or Drive in the bushes
          
 
# - Dummy Plug to be used at an empty
  Eye while extracting other bush.

  @ - Alignment of the notch in the plate

with dimple in the Coil retainer Plate &
  relative position of the brake Hose Loop
is critical as shown for correct alignment
    of Retainer plate mounting holes.
 
$ ‐ resting dolly to be used from 
  (0402BAA0002ST )Pan Hard rod kit 
 
@
 

  .
 

  $

   
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-4 
Xylo mEagle Jan 2009/Rev 1  
 

0402BAA0001ST LOWER LINK SUSPENSION TOOL KIT-XYLO Rear Suspension

 
OPERATION -
 

 
1. Arrange the Tools as illustrated in
  the operation photo below.
2. Install on Press.
  3. Rotate the press handle to Drive
out or Drive in the bush
 

Rear Bush  

           
 

Front  Bush

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-5 
Xylo mEagle Jan 2009/Rev 1  
 

0402BAA0002ST PAN HARD ROD TOOL KIT-XYLO Rear Suspension

  OPERATION -

 
1. Arrange the Tools as illustrated
  in the operation photo below.
2. Install on Press.
  3. Rotate the press handle to Drive
  out or Drive in the bush 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-6 
Xylo mEagle Jan 2009/Rev 1  
 

0402BAA0003ST UPPER LINK SUSPENSION TOOL KIT -XYLO Rear Suspension

  OPERATION -

  1. Arrange the Tools as illustrated in

the operation photo below.
  2. Install on Press.
3. Rotate the press handle to Drive
  out or Drive in the bush 

   

            

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-7 
Xylo mEagle Jan 2009/Rev 1  
 

0502DAA0001ST UNIVERSAL HANDLE - X Rear Axle

 
  OPERATION -
 

  To be used with all dollys 

   
 

 
 
 

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-8 
Xylo mEagle Jan 2009/Rev 1  
 

0502BAA0001ST CARRIER HSG EXPANDER/STRECHER-X Rear Axle

 
  OPERATION -
 

 
1. Assemble the tool on the gear carrier
  housing. 
2. Expand / collapse by following the
 
RED ARROWs shown in picture below. 
  3.   Limit is 0.50mm only 
   
 
 

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-9 
Xylo mEagle Jan 2009/Rev 1  
 

0502DAA0002ST PINION HIEGHT SETTING GAUGE-X Rear Axle

 
  OPERATION -
 

 
1. Assemble the Dial Gauge on the tool. 
  2. Put Pinion Height Master Block in the
housing. 
  3. Use the Gauge & note the reading. 

   

 
   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-10 
Xylo mEagle Jan 2009/Rev 1  
 

0502DAA0003ST PINION HIEGHT MASTER BLOCK-X Rear Axle

    OPERATION -

  1. Assemble the Dial Gauge on the tool. 

2. Put Pinion Height Master Block in the
  housing. 
3. Use the Gauge & note the reading. 
 
 
 

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-11 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0001ST DIFF CASE DUMMY BEARING-X Rear Axle

 
  OPERATION -
 

 
Dummy Differential Case bearings to be
 
used on Differential case while
  measurement of backlash. 

   

   

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-12 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0002ST DOLLY-PRESSING PINION INN CUP-X Rear Axle

 
  OPERATION -
 
 
 

  1. Put the inner pinion bearing cup in

the housing at place.
 
2. Keep the dolly on the cup.
  3. Drive the cup home using universal
handle.
 

   

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-13 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0003ST DOLLY_ PRESSING PINION OUT CUP-X Rear Axle

  OPERATION -
 

 
1. Put the outer pinion bearing cup in
 
the housing at place.
  2. Keep the dolly on the cup.
3. Drive the cup home using universal
  handle.

 
 
 

  

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-14 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0004ST DOLLY_PRESSING PINION INN CONE-X Rear Axle

 
  OPERATION -
 

 
1. Put the inner pinion bearing cone on
  the pinion tail.
2. Keep the dolly on the cone.
 
3. Drive home the cone.
 

   

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-15 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0005ST DOLLY _PRESSING DIFF CASE BRGS-X Rear Axle

    OPERATION -

 
1. Put the Diff case bearing cone on the
 
Diff case.
  2. Keep the dolly on the cone ( resting
on inner race.
  3. Drive home the cone by hammering
the dolly.
 

 
 
 

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-16 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0006ST ADAPTER _REMOVE DIFF CASE BRGS-X Rear Axle

  OPERATION -
 
 

  1. Place the Adapter between Diff case

bearings & adapter ring of the press
 
for bearing removal.
  2. Rotate the press handle clockwise to
remove the bearing.
 

   

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-17 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0007ST ADAPTER_REMOVE PINION INN BRGS-X Rear Axle

    OPERATION -

  1. Place the Adapter between inner

pinion bearing & adapter ring of the
  press for bearing removal.
2. Rotate the press handle clockwise to
 
remove the bearing.
 

   

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-18 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0008ST ADAPTER_REMOVE PINION OUT CUP-X Rear Axle

 
  OPERATION -
 

  1. Place the Adapter on pinion outer

bearing cone.
 
2. Drive out the cone by using Universal
  handle & hammering it.

   

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-19 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0009ST DOLLY_PRESSING PINION OIL SEAL-X Rear Axle

    OPERATION -

  1. Place the oil seal in the housing.

2. Drive home the seal using the Tool &
  hammering carefully.
 

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-20 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0010ST ADAPTER _REMOVE PINION INN CUP-X Rear Axle

 
  OPERATION -
 

 
1. Place the oil seal in the housing.
  2. Drive home the seal using the Tool &
hammering carefully.
 

 
 
 

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-21 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0011ST DOLLY_PRESSING T/F INBORD OIL SEAL-X Rear Axle

 
  OPERATION -
 

 
1. Place the oil seal in the Tube.
  2. Drive home the seal using the Tool &
hammering carefully.
 

 
 
 

   

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-22 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0012ST PULLER_OIL SEAL PINION /FLANGE INBORD-X Rear Axle

 
  OPERATION -
 

  1. Place the Tool jaws behind the oil

seal in the housing.
 
2. Expand the jaws using the tightening
  ring.
3. Pull out the seal by using the sledge
  hammer carefully.

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-23 
Xylo mEagle Jan 2009/Rev 1  
 

0502DAA0004ST HOLDER_END YOKE/CF-X Rear Axle

    OPERATION -

   

  1. Hold the yoke flange by inserting the

holder pins in the bolt holes on the
  flange.
2. Now with this the flange can be hold
  for loosening / tightening the flange
nut.
 

 
 
 

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-24 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0013ST PULLER_AXLE SHAFT BEARING-X Rear Axle

 
OPERATION -
 

 
1. Remove Circlip & cut the Axle Shaft
 
Bearing retainer.
  2. Mount the tool flange on to the brake
back plate.
  3. Rotate the tool handle to pull the
bearing out along with the brake back
  plate .

   

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-25 
Xylo mEagle Jan 2009/Rev 1  
 

0502CAA0014ST PRESS FOR BRG REMOVAL-X Rear Axle

  OPERATION -

 
1. Place the suitable Adapter between
 
inner pinion bearing / Differential
  case bearings & adapter ring of the
press for bearing removal.
  2. Rotate the press handle clockwise to
remove the bearing.
 

 
 
 

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.  

 Special Tool Manual MAN-00051-26 
Xylo mEagle Jan 2009/Rev 1  
 

0502AAA0001ST TOMMY BARS-X Rear Axle

    OPERATION -

   

 
To be used as levers while taking out the
 
Differential case assy. from gear carrier
  assy. as shown in the picture below

All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of whole of the present document, are

prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.