dongfeng 460 13T rear axle 中后桥维修手册-en

Service Manual for Dongfeng 460 Series Central & Rear Axle
Table of contents
I. General..................................................................................................................................................1
II. Removal and mounting of central axle final drive assembly ...............................................................11
III. Replacement of central axle driving and driven gear assembly.........................................................14
IV. Repair of inter-axle differential assembly of central axle ...................................................................34
V. Repair of inter-axle differential control mechanism assembly.............................................................39
VI. Replacement of axle shaft.................................................................................................................43
VII. Replacement of axle shaft oil seal assembly ...................................................................................45
VIII. Removal and mounting of hub brake drum assembly .....................................................................47
IX. Replacement of brake drum..............................................................................................................51
X. Replacement of hub ...........................................................................................................................53
XI. Replacement of rear hub bearing......................................................................................................56
XII. Replacement of final drive flange .....................................................................................................62
XIII. Replacement of driving bevel gear oil seal......................................................................................64
XIV. Removal and mounting of final drive assembly...............................................................................67
XV. Removal and mounting of differential assembly...............................................................................71
XVI. Replacement of differential bearing ................................................................................................76
XVII. Replacement of axle shaft gear, planetary gear and cross axle.....................................................78
XVIII. Replacement of differential housing..............................................................................................84
XIX. Repair of differential assembly........................................................................................................91
XX. Replacement of final drive housing..................................................................................................98
XXI. Replacement of driving bevel gear rear bearing ...........................................................................105
XXII. Replacement of driving bevel gear bearing seat..........................................................................107
XXIII. Replacement of driving bevel gear front bearing ........................................................................110
XXIV. Replacement of driving and driven cone gears...........................................................................115
XXV. Repair of final drive assembly......................................................................................................124
XXVI. Replacement of thrust bar assembly ..........................................................................................137
XXVII. Removal and mounting of rear axle assembly ..........................................................................138
XXVIII. Replacement of rear axle housing assembly............................................................................143
I. General
(I) Central and rear axle subassemblies
Rear axle
Central axle
1. Vent plug assembly 17. Heavy-duty spring washer 33. Rear hub oil seal assembly
2. Sealing washer-Screw plug 18.Bolt 34. Adjusting nut-Hub bearing
3. Drain plug-Oil drain 19. Heavy-duty spring washer 35. Lock washer- Hub bearing nut
4. Central axle housing assembly 20.Bolt 36. Left rear wheel bolt
5. Ball bearing-central axle output end 21. Leaf spring sliding plate-Rear axle 37. Rear brake shoe
6. Lining-Rear oil seal seat 22. Washer 38. Rear hub inner bearing inner ring
7. Oil seal seat-Output end 23. O-shaped ring- Flange assembly
8. Oil seal assembly-Output end 24. Flange assembly 39. Rear hub
9. Hollow shaft assembly 25. Plain washer 40. Rear hub outer bearing inner ring
assembly
10. Heavy-duty spring washer 26. Hexagon slot nut
41. Gear ring (rear axle) ABS gear ring
11. Bolt 27. Split pin
(central axle)
12. Heavy-duty spring washer 28. Rear axle housing assembly
42. Engagement sleeve
13. Type-I hexagon nut 29. Rear brake bottom plate assembly
43. Lining of rear axle shaft
14. Oil-resistant RTV sealant 30. Heavy-duty spring washer
44. Axle shaft oil seal assembly
15. Stud-Used to fasten the reducer 31. Bolt- used to fasten the rear brake
45. Left axle shaft of rear axle
16. Leaf spring sliding plate-Central 32. Rear oil seal seat ring
46. Bolt of rear axle shaft
axle
General 1
The central and rear axles are used to transfer the power derived from the transmission via drive shaft
(rotation and torque) to the rear wheel through the final drive, which primarily comprise the final drive
assembly, differential assembly, axle housing assembly, axle shaft and other parts.
The cast central and rear axle housings are applied. The axle shaft sleeves are fitted by pressing from
both ends of the housing, and their axial movement relative to the housing is restricted using the stop
screw.
The axle shaft is a solid shaft used to transfer the power between differential and driving wheel. Its inner
end is connected to the axle shaft gear in the differential via the spline, while its outer end flange is
connected to the driving wheel hub via studs. The axle shaft is provided with full-floating support; namely,
it only receives the torque, but no reverse load and bending moment are applied onto it. Such axle shafts
are easy for removal. To remove them, only screws on axle shaft flanges need to be undone, whilst the
wheel and axle housing will support the vehicle.
Central axle assembly
2 General
Rear axle assembly
General 3
Central axle final drive
1. Hexagon slotted thin nut 17. Rear side gear 33. Axle shaft gear- Cone gear
2. Cylindrical gear housing 18. Supporting washer-Rear side gear differential
3. Flange assembly-Input terminal 19. Bearing outer ring (used together 34. Supporting pad-Planetary gear
4. O-shaped ring with the inner ring) 35. Planetary gear-Cone gear
20. Central axle drive cylindrical gear differential
5. Oil seal seat & oil seal
assembly-Hollow shaft input end 21. Bearing seat -Driving bevel gear 36. Cross axle
6. Positioning sleeve- Driven 22.Bearing assembly 37. Rear bearing assembly-Driving
cylindrical gear bevel gear
23 Adjusting shim-Front bearing of
7. Ball bearing-Central axle input end driving bevel gear 38. Inter-axle differential control
mechanism assembly
8. Screw plug assembly-Oil drain 24. Central axle driving bevel gear
(used together with the driven cone 39. Bearing seat-Driving cylindrical
9. Screw plug-Oil level hole
gear) gear
10. Inter-axle differential housing
25. Central axle driven cylindrical gear 40. Hexagon slotted thin nut-Driving
11. Inter-axle differential front housing bevel gear
(used together with the rear housing) 26. Adjusting shim-Driving bevel gear
as necessary 41. Hexagon head bolt
12. Supporting washer-front side gear
27. Adjusting nut- Differential bearing 42. Hexagon bolt
13. Front side gear
28. Bearing outer ring (used together 43.Central axle final drive housing
14. Supporting pad-Planetary gear (used with differential bearing cover)
with the inner ring)
15. Planetary gear-Inter-axle 44. Differential bearing cover (used
29. Adjusting shim
differential with the central axle final drive
30. Central axle driven cone gear
16. Cross axle- Inter-axle differential housing)
(used together with the driving bevel
gear) 45. Cone gear differential left housing
(used with right housing)
31. Locking plate -Differential bearing
adjusting nut
32.Supporting washer-Axle shaft gear
4 General
Rear axle final drive
1. Hexagon slot nut 11. Adjusting shim-Driving bevel gear 21. Axle shaft gear supporting washer
2. Plain washer front bearing 22. Axle shaft gear-cone gear
3. Flange assembly 12. Bearing assembly differential
4. O-shaped ring 13. Adjusting nut-Differential bearing 23. Planetary gear supporting washer
5. Oil seal assembly-Driving bevel 14. Bearing assembly 24. Planetary gear-cone gear
gear 15. Locking bolt- Driven cone gear differential
6. Bearing seat- Driving bevel gear 16. Cone gear differential left housing 25. Cross axle
7. Adjusting shim- Driving bevel gear 17. Rear axle driving bevel gear 26. Cone gear differential right
housing
8. O-shaped ring 18. Rear bearing assembly-Driving
bevel gear 27. Bolt-Differential housing
9. Bearing assembly
10. Adjusting shim-Driving bevel gear 19. Spring collar for shaft 28. Locking plate 止动片-Differential
front bearing 20. Rear axle final drive housing bearing adjusting nut
29. Differential bearing cover
30. Bolt- used for differential bearing
cover
The power input into the driving axle from the transmission is firstly transferred into the final drive to
increase the torque and reduce the revolution accordingly, and the rotating axis is also altered by 90°.
Thereafter, the power is distributed to left and right axle shafts via the differential and further transferred
to wheels via the flange disc and hub at the axle shaft external end through the axle shaft.
General 5
(II) Technical parameters

Technical parameters
Item Major parameter

Center-to-center distance of leaf springs 980mm
Leaf spring positioning hole diameter 2-Φ21mm
Applicable final drive ratio 3.42/3.91/4.11/4.44/4.88/5.143/5.26/5.29/5.57/6.33
Final drive output torque 43000N·m
Offset of final drive (up-down × left-right) 38×62mm
Distance between flange end face and axle
442.5mm
center
Cross section at axle housing leaf spring
165×160mm
seat (height × width)
Leaf spring seat inclination 3°45'
Type of brake S-cam roller type
Specification of brake Φ410×220mm
Tyre bolt 10-M22
Tyre bolt circle Φ335mm
Tyre 12-20
Rim 8.50-20
Lubrication data
Part to be
Lubricant Manufacturer
lubricated
Reducer assembly GL-5 hyperbolic gear oil Dongfeng Motor Co., Ltd.
No.2 automobile universal lithium-based
Hub bearing Dongfeng Motor Co., Ltd.
grease
Adjusting arm Dongfeng Motor Co., Ltd.
grease
Cam bracket Dongfeng Motor Co., Ltd.
grease
Major adjustment data
Adjustment item Adjustment data
Gear backlash 0.30～0.40mm

Clearance between rear friction plate and brake
0.4～0.7mm
drum
6 General
Service criteria
Axle shaft of rear axle
Nominal Service Wear

Repair
Item dimensions criteria limit
limit (mm)
(mm) (mm) (mm)
Bending of axle shaft of rear axle -- <0.1mm -- 0.5mm
Hub bearing pretightening force (measured at
-- 60-90N -- --
hub bolt)
Horizontal -- <0.2mm 0.4mm
Rim runout
Vertical -- <0.2mm 0.4mm
Final drive
Nominal Service Repair Wear

Item dimensions criteria limit limit
(mm) (mm) (mm) (mm)
Backlash of driven cone gear of final drive - 0.3～0.4 0.45 -
Fit backlash between axle shaft gear bush and
- 0.21～0.31 0.6 -
differential housing
Backlash of spiral gear (transmission gear, idle
- 0.20～0.30 0.45 -
gear, transfer case driving gear)
Backlash between differential gears - 0.15～0.25 0.45 -
Backlash between driving gear and driven gear - 0.30～0.40 0.60 -
Backlash of differential gear (measured at
- 0.20～0.35 0.60 -
driving gear bolt)
Clearance between planetary gear and cross
- 0.10～0.14 0.3 -
axle
Clearance between shifting fork and
- 0.10～0.18 1.0
engagement sleeve
Clearance between inter-axle differential
- 0.06～0.13 0.6 -
housing and axle shaft gear bush (front side)
Clearance between inter-axle differential
- 0.07～0.14 0.3 -
housing and axle shaft gear bush (rear side)
Remarks: If the repair limit is reached, extra-thick brake friction plate shall be applied. Technical
parameters of wear limit and repair limit marked "+""-" mean the value to be added to or deducted from
the normal size of the part.
General 7
(III) Tightening torque

Rear axle housing and axle shaft
Part to be tightened Tightening torque (N·m)

Drain plug 130～150
Driving gear large nut 600～740
Rear brake bottom plate bolt 230～265
Air chamber bracket fastening bolt 140～170
Air chamber fastening bolt 140～180
Bearing seat bolt 140～170
Driven wheel bolt 750～850
Differential housing bolt 350～450
Axle shaft bolt 140～180
Rear adjusting nut 700
Reducer housing and axle housing connecting bolt 130～160
Brake
Item Tightening torque (N.m)

Rear brake floor fastening bolt 230～265
Front/rear brake air chamber lock nut 170～200
Front/rear brake shoe shaft lock bolt 50～70
Final drive
Part Tightening torque (N.m)

Final drive housing lock bolt 140～170
Final drive driven gear and differential housing lock
750～850
bolt
Final drive lubricating oil level inspection screw
130～195
plug
Rear axle housing drain plug 130～195
Rear axle final drive driving gear flange yoke lock
650～850
nut
Rear axle driving gear bearing cover lock bolt 160～204
Differential bearing cover lock bolt 500～550
Rear axle differential housing lock bolt and nut 350～450
Differential bearing cover lock bolt 500～550
Axle shaft lock bolt 200～260
8 General
(IV) Fault diagnosis

Rear axle system fault diagnosis
Symptoms of the
Causes Solutions
fault
The hub bearing pretightening force is too big Readjust the pretightening force
The hub bearing The bearing lacks lubrication or the incorrect
Refill or replace grease
moves grease is used.
unsmoothly Clean the bearing and refill
The bearing is contaminated by dust
grease
Check working conditions of the
The camshaft rotates unsmoothly
camshaft
The brake air chamber push rod travel is
Adjust the travel
improperly adjusted
The friction plate is too hot or degraded Replace friction plate
The braking power Check the pneumatic pipelines
The brake air pressure or volume is low
is insufficient and various air valves
The friction plate is fitted improperly Fit the friction plate properly
Lightly depress the pedal during
Water enters into the brake drum
operation to discharge the water
The friction plate or brake drum contact area is Remove the grease or replace
contaminated by oil the friction plate
The friction plate is worn to project the rivet Replace the friction plate
The friction plate surface is hardened or
Replace the friction plate
degraded
The brake drum is unevenly worn or improperly Rectify the brake drum or tighten
The brake makes fitted the bolt
strange noise The brake shoe and friction plate are in loose
Replace the rivet
contact
The brake shoe pin comes loose Tighten the pin locking screw
The hub bearing is worn Replace the hub bearing
The brake drum is deformed Replace the brake drum
The camshaft is improperly lubricated or the Refill grease or rectify faulted
The wheel moves adjusting arm can’t be returned parts
unsmoothly The brake shoe or air chamber return spring is
Replace faulted parts
broken or fatigued.
The differential backlash is incorrect Replace the pad or gear
The clearance between driving and driven
Replace the pad or gear
gears is too large
The transmission
The driving gear bearing pretightening force is
makes abnormal Adjust the pretightening force
too small
noise
The axle shaft gear, planetary gear, cross axle
Rectify or replace faulted parts
thrust gasket or others are worn or damaged
The oil level is too low Refill enough lubricating oil
The oil seal is worn, loosened or damaged Replace the oil seal
The final drive lock bolt is loosened or the Tighten the bolt or re-apply
sealant is damaged sealant
Tighten the bolt as per the
The bearing seat lock bolt is loosened
There is leakage required torque
of lubricating oil The drain plug is loosened or the lining is Tighten the screw plug or replace
damaged the lining
The axle housing is deformed due to Rectify or replace the axle
overloading housing
The vent plug is clogged or damaged Clean or replace the vent plug
General 9
Symptoms of the
Causes Solutions
fault
Tighten the retaining pin lock
The brake shoe is improperly fitted or the return
screw or replace the return
spring is damaged
spring.
The brake works
unsteadily The brake friction plate is contaminated by oil
Clean or replace the friction plate
or is degraded
The brake bottom plate is damaged Replace the brake bottom plate
Fault diagnosis of self-adjusting arm
Symptoms of the
Causes Solutions
fault
Apply the brake for many times to
The braking clearance is too large
compensate the gap in good time
The brake works
The worm shaft reverse torque is less Replaced by the self-adjusting arm of the
powerlessly
than 30N.m same model
Other causes Check the brake or braking system
The brake or new friction plate is in the The brake or new friction plate is in the
running-in period running-in period
The brake or air chamber returns The brake or air chamber returns
The brake drum is improperly improperly
too hot
Replace or recover parts to eliminate Replace or recover parts to eliminate
interference interference
The brake shoe is eccentric The brake shoe is eccentric
The brake drum is seriously out of
Replace it with the qualified brake drum
The wheel is round
locked The friction plate quality is poor Replace it with the qualified friction plate
Other causes Check the brake or braking system
The self
The self-adjusting worm shaft turns The self-adjusting worm shaft turns
adjustment is
around upon the release of the brake around upon the release of the brake
disabled
10 General
II. Removal and mounting of central axle final drive assembly

(I) Recommended tools and auxiliary materials
Tools and auxiliary

Name and model
materials
Common tools Sleeve S27, copper bar, flat shovel
Special tools ——
Testing tools Dial gauge and magnetic stand, V-shaped block, torque wrench （0~400N·m）
auxiliary materials Triangular wooden block, lubricating grease
(II) Working procedure

Removal
1. Use the triangular wooden block to hold

back the wheel.
2. Fully discharge the gear oil.

1). Remove the drain bolt A.
2) Remove the drain bolt B.
3) Remove the drain bolt C.
4). Fully discharge the gear oil.
3. Remove the drive shaft

1). Disconnect the flange used to connect the
central and rear axles.
2). Remove the drive shaft between the
transmission and central axle.
4. Remove the bearing cover, and pull out the
hollow shaft.
5. Remove the air pipe from control cover.
Removal and mounting of central axle final drive assembly 11

6. Remove the axle shaft.

1). Undo those 10 bolts used to connect the axle
shaft flange and the hub.
Notice: Bolts shall be undo crosswise.
2). Use the copper bar to lightly hit the center of the
axle shaft tail till the axle shaft is loosened.
3). Carefully take out the axle shaft.
Notice:Slowly rotate the axle shaft while its
spline is passing through the oil seal to avoid
damaging the oil seal.
7. Remove the final drive assembly

1). Remove the final drive connecting bolt.
2). Use a horizontal pulley or final drive jack.
Cleaning
1. Remove the sealing gaskets on the final drive and axle housing.
1) Thoroughly remove the sealing gaskets on the flange, final drive and axle housing.
2). Fully clean the flange surface by means of the oil shovel or absorption or other methods.
Notice: It is allowed to remove the sealing gasket from the flange surface using a scraper, but
care shall be taken to not damage the flange surface.
Mounting
1. Evenly apply the liquid sealant onto the positions as shown in the figure according to the
manufacture’s instructions.
2. Use a horizontal pulley type final drive jack

to fit the reducer onto the axle housing.
Tightening torque: 130~150N·m
1. Outer side 2. Inner side 3. Bolt hole
12 Removal and mounting of central axle final drive assembly

3. Mount the axle shaft.

4. Connect the air pipe.
5. Mount the drive shaft of the central axle front
end.
6. Mount the hollow shaft and bearing cover.
7. Mount the shifting fork and the drive shaft
between central and rear axles.
8. Refill the gear oil.

1). Open the filler plug A and horizontal plug B.
2). Fill gear oil from the hole.
Notice: The final drive shall be filled up with
85W/90 heavy-duty gear oil. To reach the level
of horizontal plug B, about 12L gear oil is
needed.
Removal and mounting of central axle final drive assembly 13

III. Replacement of central axle driving and driven gear assembly

Breakdown drawing of central axle final drive
1. Hexagon slotted thin nut 17.Rear side gear 32. Rear bearing 47. Cone gear differential
2. Plain washer-input end 18. Supporting washer- assembly-Driving bevel left housing
3. Flange assembly-Input Rear side gear gear 48. Central axle driven cone
end 19. Inter-axle differential 33. Spring collar for shaft gear
4. O-shaped ring- Flange rear housing 34. Adjusting shim-Driving 49. Differential bearing
5. Oil seal assembly- Input 20. Bearing seat-Driving bevel gear cover
end cylindrical gear 35. Central axle final drive 50. Bolt
6. Oil seal seat-Input end 21. Lining-Inter-axle housing 51. Locking plate
7. Ball bearing-Central axle differential housing 36. Cylinder –Differential bearing
input end 22. Cylindrical gear housing 37. O-shaped ring adjusting nut
8. Plug assembly-Oil drain 23. Bearing inner ring 38. Piston-Inter-axle 52. Supporting washer- Axle
9. Plug-Oil level hole assembly differential lock shaft gear
10. Inter-axle differential 24. Bearing outer ring 39. Shifting fork return 53. Axle shaft gear –Cone
housing assembly spring gear differential
11. Inter-axle differential 25. Central axle driving 40. Differential lock indicator 54. Supporting pad-
front housing cylindrical gear lamp switch Planetary gear
12. Supporting washer- 26. Positioning sleeve- 41. Cylinder seat 55. Planetary gear-Cone
Front side gear Driven cylindrical gear 42. Declutch shift shaft gear differential
13. Front side gear 27. Central axle driven 43. Shifting fork 56. Cross axle
14. Supporting pad- cylindrical gear 44. Adjusting nut-Differential 57. Cone gear differential
Planetary gear 28. Bearing seat- Driving bearing right housing
15. Planetary bevel gear 45. Outer ring-Bearing
gear-Inter-axle differential 29. Bearing assembly assembly
16. Cross axle- Inter-axle 30. Bearing assembly 46. Inner ring-Bearing
differential 31. Central axle driving assembly
bevel gear
14 Repair of central axle inter-axle differential assembly

Tools and auxiliary

Name and model
materials
Common tools Sleeve S27, copper bar, double offset ring spanner S27
Testing tools Dial gauge, magnetic stand, V-shaped block, torque wrench (0-400N.m)
Auxiliary materials Triangular wooden block, grease

Removal
1. Remove the final drive assembly.

Refer to Removal steps 1-7 of “Removal and
mounting of final drive assembly”.
2. Remove the inter-axle differential assembly.
3. Remove the inter-axle differential control

mechanism.
4. Remove the inspection hole cover.
Repair of central axle inter-axle differential assembly 15

5. Measure and record the backlash between

transmission gear and idle gear.
1) Apply grease onto the fuse, and bond it onto the
idle gear tooth face.
1. Lead wire
2). Rotate the idle gear till the fuse is pressed into
between the transmission gears, and then reverse
the idle gear to take out the fuse.
3). Use a micrometer to measure its thickness and
record it.
Requirement: Repeat he above-mentioned
operation at different points and then calculate
the average value.
Notice: The transmission gear shall be
prevented from catching the fuse. ‘
4) Use the same method to measure and record
the clearance between the transmission gear and
the transfer case drive gear.
6. Remove the final drive housing assembly.

1) Remove the final drive housing bolt.
2) Remove the final drive housing.
7. Clean the mounting surface.
1) Fully remove the sealing liquid from the
mounting surface using the washer and remove
the oil, water and other pollutants on the surface.
Notice: When removing the sealing liquid from
the mounting surface using the washer, use a
proper tool, for example, scraper, to level the
surface, but take care not to damage it.

8. Measure and record the backlash of driven

gear.
9. Remove the locking plate.
10. Make a rectification mark on the bearing

cover edge and final drive housing.
11. Remove the adjusting nut

1). Loosen the bearing cover lock bolt slightly, and
undo the adjusting nut using the differential
spanner.
1. Differential spanner

12. Remove the bolt and bearing cover.
14. Remove the transmission gear.

1). Remove the bearing lock nut.
2). Remove the transmission gear and washer
using the bolt removing hole on the bearing seat
ring.
1. Puller bolt hole
15. Remove the engine oil collector and

adjusting shim.
1. Engine oil collector

16. Remove the driving bevel gear

1). Remove the split pin and slotted nut.
2). Press out the driving bevel gear, and remove

the bearing retainer, cone roller bearing, lining,
washer and driving gear.
3). Use a bearing puller to remove the hoop and

guide bearing (only when it is necessary to replace
the bearing).
4) Use the bearing puller to remove the cone roller

bearing (only when it is necessary to repair the
bearing).

5). Remove the centring part.
6) Use the puller to remove the bearing outer seat

ring (only when it is necessary to repair the
bearing).
Outer ring
17. Remove the driven cone gear.

Notice: Used together with the driving bevel
gear.

Inspection
1. Clearance between differential gears
If the clearance exceeds the repair limit during breakdown, it is necessary to check the gear contact
mark and the wear conditions of the thrust gasket.
Repair criteria: 0.15~0.25mm
Repair limit: 0.45mm
2. Clearance between transmission gear, idle gear and transfer case driving bevel gear
If the clearance exceeds the repair limit prior to breakdown, it is necessary to check the gear contact
mark and wear conditions of the bearing.
3. Clearance between driving gear and driven gear
4. Backlash of differential gear
5. Measure the fit clearance between differential planetary gear and cross axle
Measure the inner diameter of planetary gear and outer diameter of planetary cross axle journal, and
calculate their fit clearance.
Repair limit: 0.3mm
6. Fit clearance between axle shaft gear bush and differential housing
Measure the outer diameter of axle shaft gear
bush and inner diameter of differential housing,
and calculate their fit clearance.
Notice: Left and right differential housings
must be replaced simultaneously.
Repair criteria 0.21~0.31mm
Repair limit 0.6mm
Fit clearance between inter-axle differential
planetary gear and cross axle: Measure the inner
diameter of differential planetary gear and outer
diameter of the cross axle, and calculate their fit
clearance.
Repair limit 0.3mm
7. Fit clearance between inter-axle differential axle shaft gear bush and differential housing
Measure the ourter diameter of inter-axle differential axle shaft gear bush and the internal diameter of
differential housing, and calculate their fit clearance.
Front

Wear limit 0.6mm

Rear
Wear limit : 0.3mm
8. Clearance between shifting fork and engagement sleeve
Measure the thickness of shifting fork and width of engagement sleeve groove, and then calculate the
clearance between them.
Wear limit 1.0mm
Return spring
Measure the free length of return spring
Standard size 78.8mm
Wear limit 73mm

The below is the final drive assembly drawing:

1.Flange washer 29. Split pin 57.Shifting fork

2. Mating flange 30. Homed nut 58. Pin
3. Oil seal 31. Cross axle 59. Retaining ring
4. O-shaped ring 32. Driving pinion 60. Declutch shift shaft
5. Oil seal grommet 33.Discharge valve 61. Plug
6. Gasket 34. Gasket 62. Differential housing (right)
7. Roller bearing 35. Rear axle housing cover 63. Pinion
8. Inter-axle differential cover 36. Shim 64. Thrust ring
9. Pinion 37. Tapered roller bearing 65. Pinion shaft
10. Thrust ring 38. Shim 66. Driving gear
11. Inter-axle differential housing 39. Tapered roller bearing 67. Differential housing (left)
(front) 40. Bush 68. Planetary gear
12. Gasket 41. Tapered roller bearing 69. Thrust ring
13. Filler plug 42. Driving bevel gear 70. Bearing cover
14. Shim 43. Guide bearing 71. Cylindrical roller bearing
15. Bearing bracket 44. Chuck 72. Adjusting nut
16. Tapered roller bearing 45. Cylinder block 73. Lock plate
17. Shifting fork 46. Spring 74. Split pin
18. Sliding clutch 47. Nut 75. Homed nut
19. Hollow shaft 48. Plain washer 76. Washer
20. Thrust ring 49. Felt lubricator 77. O-shaped ring
21. Differential planetary gear (front) 50. O-shaped ring 78. Tapered roller bearing
22. Thrust ring 51. Felt greaser 79. Intermediate gear
23. Pinion 52. O-shaped ring 80. Bush
24. Gasket 53. O-shaped ring 81. Adjusting shim
25. Discharge valve 54. O-shaped ring 82. Intermediate gear shaft
26. Planetary gear (front) 55. Filler plug 83. Lock plate
27. Rear axle housing cover 56. Gasket
28. Transfer case gear
Fitting
1. Fit the driving bevel gear assembly.
1). Press the driving bevel gear front bearing outer

ring into the bearing seat.
1. Bearing retainer

2) Press the driving bevel gear front bearing inner

ring onto the driving bevel gear.
3). Fit the tapered roller bearing, lining, gasket,

bearing seat and driving gear onto the driving
bevel gear.
1. Adjusting shim
4). Tighten the slotted nut
Tightening torque 650~850N·m
5). Measure the pre-tightening force of driving

bevel gear bearing. If the measured pre-tightening
force is not within the standard range, it is
necessary to break down the thickness of adjusting
shim and then check the pre-tightening force.
Repair criteria 30~35N·m
Notice: The shim thickness is ranged from

1.700mm to 2.300mm, with an increment of
0.0125mm; there are altogether 49 shims.

6). Fit the split pin.

Notice: If the pin hole of split pin is not aligned with the nut slot, slowly tighten the nut till they
are aligned.
7) Fit the guide bearing and elastic washer.

Notice: Do direct the guide bearing part
number toward the spring collar.
1. Mark
2. Fit the driven gear.

Notice: Apply lock sealant onto threads of the
driven cone gear lock bolt.
3. Fit the cylindrical gear housing assembly.

1). Fit the bearing outer ring.
1. Idle gear

2). Fit the O-shaped ring.
1. O-shaped ring
3). Fit the tapered roller bearing into the idle gear,
mount the adjusting shim and lining, place the
pre-assembled idle gear into the cylindrical gear
housing, and put the idle gear shaft through the
housing such that the thin cut on the idle gear shaft
is aligned with the housing lock plate bolt.
4). Fit the lock plate.
5). Fit the shim and slotted nut, tighten the nut, and
then rotate the idle gear by two or three turns to
disengage and hold the bearing at a proper
position.

6). Measure the pre-tightening force of the idle

gear. If the torque is not within the specified range,
add or delete shims till the correct pre-tightening
force is obtained.
Notice: There are 25 adjusting shims, with a
thickness increment of 0.025mm, totaling up to
1.600~2.200mm,
Repair criteria 15~30N·m
7). Lock the slotted nut with a split pin. If the split
nut pin hole is not aligned, slowly tighten the nut till
it is aligned.
8). Fit the tapered roller bearing.
1. Driving cylindrical gear
4. Fit the central axle final drive housing

assembly.
1). Fit the engine oil tank and shims, and ensure
the quantity of shims. The correct quantity of shims
has been marked out on the differential housing.
1. Engine oil collector

1. Correct quantity of shims
2). Fit the driving gear assembly, and adjust shims.

Tighten the bearing retainer bolts.
Tightening torque 120~140N·m。
3). After the axle shaft bearing outer ring is fitted, fit
the differential assembly onto the final driving
housing.
4). Fit the adjusting nut, and temporarily tighten the

bearing cover.
Notice: Mounting marks made prior to the
decomposition of the bearing cover shall be
aligned.

5. Adjust the gear backlash.

1). Undo the right adjusting nut, tighten the left
adjusting nut, and use the differential spanner to
adjust the gear backlash to zero.
2). Undo the left adjusting nut, tighten the right
adjusting nut, adjust the backlash and maintain it
within the repair criteria.
Repair criteria 0.3~0.4mm.
Method of increasing the backlash: Undo the

backlash adjusting nut and adjust the right
adjusting nut (i.e., move the driven cone gear far
from the driving bevel gear).
Method of reducing the backlash: Undo the right

adjusting nut and tighten the left adjusting nut (i.e.,
approach the driven cone gear to the driving bevel
gear).
1. Differential spanner
3) After the backlash is adjusted, evenly tighten left

and right adjusting nuts to regulate the
pre-tightening load till the load meets the repair
criteria.
Repair criteria 80~120N.
4). Adjust the thickness of shims.
5).Make two or three points on the mating surface of the driven gear using the red paint, and check the
meshing contact area of gears. If the contact area is improper, add or delete shims between the driving
bevel gear bearing seat and the reducer housing till a proper contact area is obtained.
Notice: If there is a significant difference at two adjacent points of the driven cone gear, it is
necessary to replace the driven and driving cone gars till there is no difference. Thereafter, check
the backlash again.
Thickness mm
Single-piece type 0.5,1.0
Multi-piece type 0.1,0.15,0.5

6). Tighten the bearing cover lock bolt.
Tightening torque 450~500N·m.
6. Refit the lock plate.
Notice: Do not bend the locking piece to have it

seize the adjusting nut.
7. Fit the reducer housing.

1). Apply the liquid sealant onto the differential
housing bolt. Apply the sealant onto the mating
surface between reducer housing and axle
housing and the lock bolt.
2). Apply the sealant onto the immediate area of

the inlet and outlet of the oil pump as per positions
shown in the figure, if required.

8. Fit the bearing support and shims

1). Tighten three bolts using the specified torque.
2). Rotate the driving gear housing to locate the
bearing at a proper position.
3). Measure the load and make sure that it is zero.
If the gasket is not to be adjusted, place a
micrometer on the idle gear, and rotate the idle
gear counterclockwise till the reading on the
micrometer is the minimum.
4). Pry the idle gear at the inspection window, and
check whether the gear clearance is within the
specified range. If not, add or delete shims till the
correct clearance is obtained.
Axial clearance 0.15~0.17mm.
5). Tighten the remaining bearing support bolts.
9. Measure the clearance between idle gear,
driving cylindrical gear and central axle driving
bevel gear.
Repair criteria 0.15~0.30mm.
10. Fit the inspection hole cover.
11. Fit the control cover assembly with shifting
fork and tighten the bolt.
12. Fit the intermediate shaft differential

assembly.
13. Fit the oil pump.

Apply the liquid sealant evenly as per the
manufacturer’s instructions and the positions
shown in figure.

14. Fit the engine oil collector.
Notice: Do apply the liquid sealant before

mounting.
1. Sealant width: 1.5-2mm
15. Fit the oil drain plug.
Tightening torque A 90~120N·m
Tightening torque B 30~150N·m
Tightening torque C 100~120N·m
16. Fit the final drive assembly.

Refer to mountings steps 1-8 of “Removal and
mounting of final drive assembly”.

IV. Repair of inter-axle differential assembly of central axle

Tools and auxiliary Name and model

materials
Common tools Copper bar
Testing tools Dial gauge, magnetic stand, V-shaped block, torque wrench (0-400N.m)
Auxiliary materials

Removal
1. Remove the inter-axle differential assembly.
Refer to removal steps 1-2 of “Replacement of driving and driven cone gear assembly”.
2. Remove the flange.
3. Remove the oil seal seat.
34 Repair of inter-axle differential assembly of central axle

4. Use the hammer head covered by soft metal

to lightly knock out the intermediate shaft final
drive housing along its circumference.
5. Remove the ball bearing from the
intermediate shaft final drive housing.
6. Dismantling the intermediate shaft

differential housing assembly, and then
measure the clearance between the differential
axle shaft gear and driving gear.
Notice: With the planetary gear shaft at its
mounting position, measure the backlash for
many times.
7. Remove the planetary gear assembly,

differential axle shaft gear and thrust washer.
8. Remove the thrust washer and differential

axle shaft gear from the planetary gear.
Repair of inter-axle differential assembly of central axle 35

Mounting
1. Refit the planetary gear and thrust gasket.
2. Mount the bearing gasket and axle shaft gear

onto the differential housing. Notice: Ensure
that the axle shaft gear can rotate freely.
3. Mount the planetary gear assembly.
4. Measure the differential backlash, and

ensure that the measured value is within the
repair criteria.
Notice: When measuring the backlash, press
the cross axle and differential housing.

5. Mount the axle shaft gear, washer and

differential housing. Align marks on left and
right differential housings. Use a soft-faced
hammer to lightly knock in them.
6. Tighten the nut.
7. Mount the tapered roller bearing and

intermediate shaft differential assembly.
8. Mount the oil seal and retainer.

1). Mount the oil seal.
2). Mount the oil seal retainer.
3). Tighten the retainer bolt.
1. Oil seal 2. Bearing 3. Ball bearing

support
Repair of inter-axle differential assembly of central axle 37

9. Mount the flange.

1). Mount the gasket, mating flange and O-shaped
ring.
2). Tighten the flange bolt.

V. Repair of inter-axle differential control mechanism assembly

Tools and auxiliary materials Name and model
Common tools Copper bar
Testing tools
Auxiliary materials

Removal
1. Remove the inter-axle differential control mechanism assembly.
Refer to steps 1-3 of “Replacement of driving and driven gear assembly”.
1. Remove the cylinder..

1). Remove the plug.
2). Remove the cylinder barrel, O-shaped ring and
return spring.
2. Remove the nut, gasket and piston.
Repair of inter-axle differential control mechanism assembly 39

3. Remove the felt and O-shaped ring.
1. Felt oil seal 2.O-shaped 3.O-shaped

ring ring
4. Remove the shifting fork and declutch shift

shaft.
1). Remove the clamp ring, and pull the declutch
shift shaft out of the screw plug.
2). Remove the declutch shift shaft, O-shaped ring,

screw plug and shifting fork in the forward
direction.
Mounting
1. Mount the shifting fork.
1). Put the shifting fork into the control cover.
2). Insert the declutch shift shaft into the shifting
fork hole.
Notice: Do not locate the declutch shift shaft
end wrongly.
40 Repair of inter-axle differential control mechanism assembly

2. Mount the pin and snap spring.
3. Mount the felt and O-shaped ring.
1. Felt oil seal 2.O-shaped 3.O-shaped

ring ring
4. Mount the piston & washer assembly.

1). Mount the piston.
2). Tighten the nut.
5. Mount the cylinder.

1). Mount the O-shaped ring and return spring into
the cylinder.
2). Mount the cylinder.
3). Ensure that they are Mounted reliably.
Notice: Carefully fit the cylinder onto the
piston, and avoid rolling up the felt.
Repair of inter-axle differential control mechanism assembly 41

6. Mount the inter-axle differential control

mechanism assembly.
1). Mount the inspection hole cover.
2). Mount the control cover & shifting fork
assembly, and tighten the bolt.
42 Repair of inter-axle differential control mechanism assembly

VI. Replacement of axle shaft

(I) Recommended tools and auxiliary materialss

materialss
Common tools Sleeve S27, copper bar, flat shovel
Testing tools Dial gauge and magnetic stand, V-shaped block, torque wrench (0-400N.m)
Auxiliary materialss Triangular wooden block, grease

Removal
1. Hold back the rear wheel.

1). Park the vehicle on a flat road surface, and
apply the hand control valve lever.
2). Use triangular wooden block to hold back rear
wheels.
2. Remove the axle shaft of rear axle.

shaft flange and hub.
Notice: Undo bolts crosswise.
2). Use the copper hammer to lightly hit the center
of rear axle shaft till the axle shaft is loosened.
3). Lightly pull out the axle shaft.
Notice: Slowly rotate the axle shaft whist its
damaging the seal.
Replacement of axle shaft 43

Inspection
1. Check the axle shaft.
1). Clean the axle shaft.
2). Check whether the axle shaft is cracked and
whether the spline tooth is worn.
Notice: If the shaft is cracked or the spline is
worn, replace the axle shaft.
3). Measure the radial runout of the axle shaft.

(1) Place the axle shaft over two V-shaped blocks.
(2) Use the dial gauge to measure the central
runout of the axle shaft.
Standard size ≤1mm
Wear limit: 1.5mm
Notice: If the radial runout exceeds the wear

limit, rectify or replace the axle shaft.
2. Check the axle shaft bolt.

1). Visually check whether the bolt thread slips.
Notice: If the axle shaft bolt thread slips, replace the bolt.
Mounting
1. Replace the axle shaft lining
1) Use the flat shovel to remove the old axle shaft
lining.
2). Apply grease onto the mating face between
axle shaft and hub, and position a new axle shaft
lining.
2. Fit the axle shaft.

1). Lightly insert the axle shaft into the axle shaft
sleeve.
Notice: Take care not to damage the axle shaft
oil seal.
44 Replacement of axle shaft

VII. Replacement of axle shaft oil seal assembly

(I) Recommended tools

materials
Common tools Sleeve S27, flat-head screwdriver, iron hammer, copper bar
Testing tools Torque wrench (0~400N·m)
Auxiliary materials Adhensive tape, grease

Removal
1. Remove the axle shaft

Refer to the replacement of axle shaft.
2. Remove the axle shaft oil seal.

1). Slantwise insert the flat-head screwdriver
whose head is wrapped with adhensive tape into
the lip of axle shaft oil.
2). Pry out the axle shaft oil seal.
Replacement of axle shaft oil seal assembly 45

Mounting
1. Mount the axle shaft oil seal.
1). Clean the oil seal mounting position of axle
shaft sleeve.
2). Apply a little of grease onto the lip of a new oil
seal.
Notice: Do not apply grease onto the sealing
surface of the oil seal.
3). Fit the axle shaft oil seal into the axle shaft
sleeve.
Notices:
1. Do not knock the oil seal slantwise.
2. Ensure that there are no foreign matters
between the axle shaft sleeve edge and oil seal.

Refer to the replacement of axle shaft.
46 Replacement of axle shaft oil seal assembly

VIII. Removal and mounting of hub brake drum assembly

Tools and auxiliary

Name and model
materials
Sleeve S27/S36, high-torque wrench, phillips screwdriver, jack, split

Common tools
heads , iron hammer, copper bar
Hub bearing nut locking tool, hub inner and outer bearing pre-tightening
Special tools
sleeve hub puller
Torque wrench (110~800N·m）, vernier caliper（0~500mm）, spring balance

Testing tools
（0~100N）
Auxiliary materials Triangular wooden block, grease, oil basin, gasoline
Removal
1. Remove the rear wheel.
Refer to the removal step 1 of axle shaft
replacement.

Notice: Undo bolts crosswise.
2). Use the copper hammer to lightly hit the center
of rear axle shaft till the axle shaft is loosened.
3). Carefully take out the axle shaft.
damaging the seal.
3. Release the parking brake.
1). Release the hand control valve handle to
deactivate the parking brake.
Removal and mounting of hub brake drum assembly 47

4. Remove the hub outer bearing.

1). Undo 3 screws, and remove the hub bearing
nut lock washer.
2). Use the hub bearing nut tool to remove the rear
hub bearing adjusting nut.
3). Fit a hub puller between hub and axle shaft

sleeve, slowly rotate the puller bolt clockwise using
the handle and lightly pull out the hub brake drum
assembly.
4). Remove the hub puller.
5). Remove the hub outer bearing.
Notice: Use a piece of clean duster cloth to
wrap the bearing.
5. Remove the hub brake drum assembly.

1). Take off the hub brake drum assembly.
Notice: As the hub brake drum is heavy, two
operators are needed to carefully take it off.
48 Removal and mounting of hub brake drum assembly

Mounting
1. Mount the hub brake drum assembly.
1). Put the hub brake drum assembly through the
axle shaft sleeve and fit it in place.
operators are needed to fit it.
2. Mount the hub outer bearing.

1). Put the lubricated hub outer bearing through
the hub cavity.
2). Press the hub outer bearing pre-tightening
sleeve against the hub outer bearing, and knock
the sleeve with a hammer till the outer bearing is
fitted in place.
3). Fit the rear hub bearing adjusting nut.
3. Adjust the hub bearing clearance.

1). Tighten the hub bearing adjusting nut whilst
rotating the hub to fit the bearing in place.
2). Loosen the nut by 1/6-1/4 turn, and rotate the

hub alternatively in positive and negative directions
to bring the hub bearing roller into contact with the
inner and outer ring raceway; at this moment, the
hub shall be able to rotate freely without obvious
axial runout and oscillation.
3). Use 3 screws to mount the lock washer.

Notice: The lock washer shall be aligned with
the hole on adjusting nut.
4). Rotate the hub by 2-3 turns.
Removal and mounting of hub brake drum assembly 49

5). Use the spring balance to measure the starting

tangential force at the hub bolt.
Standard tangential force 30~75N
Notice: Where the starting force is not within

the specified range, the pre-tightening force
shall be readjusted, followed by another
measurement of starting force.
4. Adjust the brake clearance. Thickness

gauge
1). Rotate the adjusting arm worm shaft clockwise
till no further movement is allowed. Adjust
clearance
2). Remove the rear dustproof cover plug.
3). Rotate the adjusting arm work shaft
counterclockwise, and measure the clearance
between brake drum and brake shoe friction plate
using the thickness gauge.
Standard clearance 0.6~0.9mm

1). Lightly insert the axle shaft into the axle shaft
sleeve.
oil seal.
2). Fit those 10 axle shaft lock bolts.
3). Tighten the axle shaft lock nut in three
operations diagonally.
6. Mount the rear wheel by making reference to

the removal and mounting of rear wheel
assembly.
50 Removal and mounting of hub brake drum assembly

IX. Replacement of brake drum

Tools and auxiliary

Name and model
materials
Sleeves S27/S36, high-torque wrench, phillips screwdriver, jack, split

Common tools
Special tools
sleeve hub puller

Testing tools
（0~100N）

Removal
Refer to Removal steps 1 through 5 of “Removal and mounting of hub brake drum assembly”.
2. Remove the brake drum.
1). Remove the hub bolt.
2). Remove the brake drum from the hub brake drum assembly.
Inspection
1. Check the brake drum.
1). Check whether the brake drum is broken.
Notice: If the brake drum is broken, replace it.
2). Measure the brake drum inner diameter using a
vernier caliper.
Standard size 400mm
Wear limit 404mm
Notice: If the measured value is higher than the

wear limit, replace the brake drum.
Replacement of brake drum 51

Mounting
crank hole
1. Mount the brake drum. Advanced
gear
1). Use those 10 hub bolts to fix the brake drum
Tool rest
onto the hub.
2. Bore and grind the brake drum.
1). Bore and grind the hub brake drum on the Base and power
boring and grinding machine.
Notice: The hub brake drums shall be co-axial
and concentric.
3. Mount the hub brake drum assembly.
Refer to mounting steps 1-6 of “Removal and
mounting of hub brake drum assembly”.
52 Replacement of brake drum

X. Replacement of hub
Tools and auxiliary

Name and model
materials

Common tools
Special tools
sleeve hub puller

Testing tools
（0~100N）

Removal

Refer to Removal Steps 1-5 of “Removal and
2. Remove the rear hub oil seal.

1). Use a slotted screwdriver to pry out the rear
hub oil seal from the rear hub.
Replacement of hub 53
3. Remove the rear hub bearing outer ring.

1). Use a copper bar to knock out the hub bearing
outer ring from the rear hub inner wall.
4. Remove the rear hub.
1). Remove those 10 hub bolts.
2). Remove the rear hub from the hub brake drum
assembly.
Inspection
1. Check the hub.
1). Check whether the hub is broken.
Notice: If the hub is broken, replace it.
2) Place a dial gauge such that its probe rests
against the hub (as shown in the figure), rotate the
hub and record the deflection reading as indicated.
End face runout Less than 1.5mm
Radial runout Less than 1.5mm

1. Radial runout 2. End face runout
Notice: If the required value is exceed, replace measuring point measuring point
the hub.
Mounting
1. Mount the rear hub.
1). Align the rear hub and brake drum bolt holes.
2). Use the copper bar to fit these 10 rear hub
bolts.
2. Mount the rear hub bearing outer ring.
1). Use the copper bar to knock the hub bearing
outer ring in place.
54 Replacement of hub
3. Mount the rear hub oil seal.

1). Apply grease onto the lip of oil seal.
2). Use the copper bar to knock the oil seal into the
hub cavity.
Notices: 1. Fit the oil seal flatly.
2. Ensure that no foreign matters exist between
the hub inner edge and oil seal.
4. Mount the rear hub brake drum assembly.

Refer to Mounting Steps 1-6 of “Removal and
Replacement of hub 55
XI. Replacement of rear hub bearing

Tools and auxiliary

Name and model
materials

Common tools
Special tools
sleeve hub bearing remover, hub puller, hub oil seal mounter
Testing tools Torque wrench (110~800N·m）, spring balance（0~100N）
Removal
1. Remove the rear wheel.
Refer to the removal and mounting of rear wheel
assembly.

Notice: Bolts shall be loosened crosswise.
2) Use the copper bar to lightly hit the center of
rear axle shaft till the axle shaft is loosened.
3). Lightly pull out the axle shaft.
damaging the seal.
3. Release the parking brake.
1). Release the hand control valve handle to
deactivate the parking brake.
56 Replacement of rear hub bearing

4. Remove the rear hub outer bearing.

1). Undo these 3 screws and remove the rear hub
bearing nut lock washer.
2). Use the rear axle hub bearing nut tool to

remove the hub bearing adjusting nut.
3). Fit a hub puller between hub and axle shaft

sleeve, slowly rotate the puller bolt clockwise using
the handle and lightly pull out the hub brake drum
assembly.
4). Remove the hub puller.
5). Take out the hub outer bearing.
wrap the bearing.
5. Remove the rear hub brake drum assembly.

1). Take off the hub brake drum assembly from the
rear axle.
operators are needed to carefully take it off.
Replacement of rear hub bearing 57

6. Remove the rear hub inner bearing.

1). Fit the rear axle hub bearing remover, use two
claws of the remover to catch the oil seal seat ring,
and support the front end on the axle shaft sleeve.
2). Use the handle to slowly tighten the adjusting
bolt of rear axle hub bearing remover clockwise,
and pull out the hub inner bearing.
3). Remove the hub bearing remover.
4). Remove the hub inner bearing and oil seal seat
ring.
wrap the bearing.
7. Remove the rear hub oil seal.

1). Use a slotted screwdriver to pry out the rear
hub oil seal from the rear hub.
8. Remove the rear hub bearing outer ring.

1). Find out those two gaps on the hub oil
chamber.
2). Use the copper bar to knock out the hub
bearing outer ring from the rear hub inner wall.
Inspection
1. Clean the removed parts.
2. Check the hub bearing.
1). Check whether the bearing rotates freely and
whether it bears burning marks; if necessary,
replace the hub bearing.
Notice: If the bearing can’t rotate freely or
bears burning marks, it shall be replaced.
3. Check the hub bearing adjusting nut.
1). Screw the hub bearing nut into the axle shaft
sleeve, and check whether the thread is sliding.
Notice: If the thread is sliding, replace the hub
bearing adjusting nut.

Mounting
1. Mount the rear hub bearing outer ring.
1). Use a copper bar to knock the hub bearing
outer ring in place.
2. Mount the rear hub oil seal.

1). Apply grease onto the lip of oil seal.
2). Use a cooper bar to knock the oil seal into the
hub cavity.
Notices:
1. Fit the oil seal flatly.
2. Ensure that there are no foreign matters
between hub inner edge and oil seal.
3. Lubricate the hub bearing.

1). Use the grease to fully lubricate the hub inner
and outer bearings.
Notice: Apply the grease evenly to ensure
sufficient lubrication.
2). Fill a proper amount of grease into the hub
cavity.

4. Mount the rear hub inner bearing

1). Put the oil seal seat ring through the axle shaft
sleeve, and use the hub inner bearing
pre-tightening force to fit the ring in place.
2). Put the lubricated hub inner bearing through the
axle shaft sleeve, and use the hub inner bearing
pre-tightening force to fit the bearing in place.
Notice: After the bearing is fitted in place (flush
against the shaft end), remove surplus grease.
5. Mount the rear hub brake drum assembly.

1). Put the hub brake drum assembly through the
axle shaft sleeve and fit it in place.
operators are needed to mount it.
6. Mount the rear hub outer bearing.

1). Put the lubricated hub outer bearing through
the hub cavity.
2). Press the hub outer bearing pre-tightening
sleeve against the hub outer bearing, and knock
the sleeve with a hammer till the outer bearing is
fitted in place.
3). Fit the rear hub bearing adjusting nut.
7. Adjust the rear hub bearing clearance.

1). Tighten the hub bearing adjusting nut whilst
rotating the hub to fit the bearing in place.
2). Loosen the nut by 1/6-1/4 turn, and rotate the

hub alternatively in positive and negative directions
to bring the hub bearing roller into contact with the
inner and outer ring raceway; at this moment, the
hub shall be able to rotate freely without obvious
axial runout and oscillation.

3). Use 3 screws to fit the lock washer.

Notice: The lock washer shall be aligned with
the hole on adjusting nut.
4). Rotate the hub by 2-3 turns.
5). Use the spring balance to measure the starting

tangential force at the hub bolt.
Standard tangential force 30~75N
Notice: Where the starting force is not within

the specified range, the pre-tightening force
shall be readjusted, followed by another
measurement of starting force.

1) Lightly insert the axle shaft into the axle shaft
sleeve.
oil seal.
2). Fit those 10 axle shaft lock bolts.
3). Tighten the axle shaft lock nut in three
operations diagonally.
9. Mount the rear wheel by making reference to

the removal and mounting of rear wheel
assembly.

XII. Replacement of final drive flange

Tools and auxiliary

Name and model
materials
Common tools Sleeve S70, double offset ring spanner S21, copper bar, pry bar
Testing tools Torque wrench （110~800N·m）
Auxiliary materials Triangular wooden block

Removal

wheels.
2. Disengage the drive shaft.

1). Make mating marks on the drive shaft sliding
yoke and on the final drive flange connected to the
yoke.
2). Remove these 4 nuts used to connect the
flange and drive shaft, and disengage the drive
shaft from the rear axle.
62 Replacement of final drive flange

3. Remove the final drive flange.

1). Remove the driving bevel gear nut and gasket.
2). Remove the flange from the final drive.
Mounting
1. Mount the final drive flange.
1). Fit the flange onto the final drive.
2). Tighten the flange cone gear nut.
3). Lock the nut edge.
2. Connect the drive shaft.

1), By aligning with mating marks, use 4 nuts to
connect the drive shaft and final drive flange.
Replacement of final drive flange 63

XIII. Replacement of driving bevel gear oil seal

Tools and auxiliary

Name and model
materials
Common tools Sleeve S70, double offset ring spanner S21, copper bar, pry bar
Removal
wheels.

yoke and on the differential housing flange
connected to the yoke.
64 Replacement of driving bevel gear oil seal


1). Remove the driving bevel gear nut and gasket.
2). Remove the flange from the final drive.
4. Remove the driving bevel gear oil seal.

1). Remove one O-shaped ring.
2). Use the pry bar to remove the driving bevel
gear oil seal from the driving cone gar bearing
seat.
Mounting
1. Mount the driving bevel gear oil seal.
1). Clean the oil seal mounting base hole in the
inner wall of driving bevel gear bearing seat.
2). Apply grease onto the oil seal lip.
3). Lightly press the oil seal into the oil seal seat
hole and ensure that the oil seal outer surface is
flush with the bearing seat plane.
4). Fit a new O-shaped ring.
Replacement of driving bevel gear oil seal 65 65


2). Fit the gasket and driving bevel gear nut.

1), By aligning with mating marks, use 4 nuts to
connect the drive shaft and final drive flange.
66 Replacement of driving bevel gear oil seal

XIV. Removal and mounting of final drive assembly

Tools and auxiliary materials Name and model
Sleeves S21/S18, double offset ring spanner S21, copper bar, final drive
Common tools
jack and pry bar
Auxiliary materials Triangular wooden block, sealant

Removal

wheels.
2. Discharge the rear axle gear oil.

1). Remove the oil drain plug to fully discharge the
rear axle gear oil.
Removal and mounting of final drive assembly 67


yoke and on the differential housing flange
connected to the yoke.
4. Remove left and right axle shafts by making

reference to the replacement of axle shaft.
5. Remove the rear axle transverse stabilizer
bar.
Refer to the replacement of rear axle transverse
stabilizer bar.
6. Remove the right energy-storage spring
brake air chamber.
Refer to the replacement of spring brake air
chamber.
7. Separate the brake pipeline bracket.

1). Remove these 2 nuts.
2). Remove the brake pipeline bracket from the
final drive housing.

1). Remove these 10 bolts and 2 nuts.
2). Use the final drive jack to pull the final drive
assembly from the rear axle housing.
68 Removal and mounting of final drive assembly

Mounting
1. Mount the final drive assembly.
1). Use the flat shovel to remove residual sealant
on the mating face between reducer and axle
housing.
2). Apply new sealant onto the mating surface
between reducer and axle housing and onto the
fastening bolts.
3). Use the final drive jack to fit the final drive
assembly into the axle housing.
4). Mount these 10 bolts and 2 nuts.
2. Mount the brake pipeline bracket.

1). Use 2 nuts to fit the brake pipeline bracket onto
the final drive housing.
3. Mount the right energy-storage spring brake

chamber.
Refer to replacement of spring brake air chamber.
4. Mount the rear axle transverse stabilizer bar.
stabilizer bar.
5. Mount the rear axle left and right axle shafts.

Refer to the replacement of axle shafts of rear
axle.
Removal and mounting of final drive assembly 69


1). Align the mating marks on drive shaft sliding
yoke and final drive flange.
2). Use 4 bolts to connect the flange and drive
shaft.
7. Refill rear axle gear oil.

1). Remove the filler plug, and refill rear axle gear
oil.
Filling quantity 14L of 85W/90GL-5

heavy-duty
automobile gear oil
2). Tighten the drain plug.
1. Filler plug 2. Drain plug
70 Removal and mounting of final drive assembly

XV. Removal and mounting of differential assembly

Tools and auxiliary

Name and model
materials
Sleeves S21/S27/S30/S34/S36, final drive jack, pneumatic spanner,

Common tools
copper bar, iron hammer
Special tools Differential spanner
Torque wrench （110~850N·m）, magnetic stand and dial gauge, spring

Testing tools
balance (0-150N)
Auxiliary materials Grease, gasoline, thread sealant

Removal

Refer to the removal and mounting of final drive
assembly.
2. Check the backlash of driving and driven

cone gears.
1). Use the dial gauge to measure the backlash of
driving and driven gears on four tooth faces evenly
distributed on the driven cone gear, and record the
results.
Standard backlash 0.30~0.40mm
Removal and mountmounting of differential assembly 71

3. Remove the Locking plate.

1). Remove the differential bearing cover Locking
plate.
4. Remove the differential bearing adjusting

nut.
1). Undo the bearing cover lock bolt.
2). Use the differential spanner to remove the
differential bearing adjusting nut.
5. Remove the differential bearing cover.

1). Mark mounting marks on the differential bearing
cover and final drive housing.
2). Remove bearing cover bolts on both sides.
3). Remove the differential bearing cover.

Notice: Bearing covers shall be placed on two
sides to avoid confusion.
72 Removal and mountmounting of differential assembly

6. Remove the differential & driven cone gear

assembly.
1). Remove the differential & driven cone gear
assembly.

1). Undo these 16 bolts of driven cone gear.
2). Use the copper bar to lightly and evenly knock
the mating face between driven cone gear and
differential housing to remove the driven cone
gear.
Notice: Place the driven cone gear flatly to
avoid damages or deformation of gears due to
impacts.
3). Remove the differential assembly.
Mounting
1. Mount the driven cone gear.
1). Mount the driven cone gear onto the differential
housing, and have it fit against the differential
housing contact surface.
2). Apply the thread sealant onto these 16 bolts,
screw in them by 2-3 threads, and then use the
pneumatic spanner to tighten them crosswise.
Notice: The fit clearance between driven cone

gear and left housing shall not be higher than
0.2mm, and there shall be no clearance
between bolt end face and differential housing.

2. Mount the differential & driven cone gear

assembly.
1). Fit the differential & driven cone gear assembly
into the final drive housing.
3. Mount the differential bearing cover.

1). Apply lubricating oil onto the bearing roller
evenly.
2). Fit the differential bearing adjusting nut.
Notice: The differential housing, adjusting nut
and bearing cover are provided with the same
thread pitches.
3). Align the bearing cover mounting marks, and
use 2 bolts to fit the differential bearing cover.
Notice: Do not tighten the bolt now.
4. Adjust the backlash of driving and driven

cone gear
1). Loosen the right adjusting nut and tighten the
left adjusting nut to adjust the backlash to zero.
2). Loosen the left adjusting nut and tighten the
right adjusting nut to regulate the backlash.
3). Increase the backlash: Loosen the left adjusting

nut and tighten the right adjusting nut.
4). Reduce the backlash: Loosen the right
adjusting nut and tighten the left adjusting nut.
5). Adjust the differential adjusting nut equally till
the required driven gear backlash is obtained.
5. Adjust the pre-tightening force of differential

bearing
1). Use the differential spanner to tighten left and
right adjusting nuts evenly and regulate the
differential bearing pre-tightening force.
74 Removal and mountmounting of differential assembly

2). Hook the driven cone gear bolt onto the spring
balance hook, rotate the differential assembly, and
measure the tangential starting force
Tangential starting force 80~120N
3). Tighten the bearing cover bolt.
6. Fit the locking plate.

1). Fit the differential bearing cover locking plate.
Notice: Do not bend the locking plate and have

it fix the adjusting nut.

Refer to the removal and mounting of final drive.

XVI. Replacement of differential bearing

Tools and auxiliary

Name and model
materials
Sleeves S21/S27/S30/S34/S36, final drive jack, bearing puller, pneumatic

Common tools
spanner, copper bar, iron hammer

Testing tools
balance (0-150N)

Removal

assembly.

assembly.
Refer to the removal and mounting of differential
assembly.
76 Replacement of differential bearing

3. Remove the differential bearing.

1). Fix the differential onto the bench clamp.
2). Use the bearing puller to remove bearings on
both sides of the differential.
Mounting
1. Mount the differential bearing.
1). Heat the bearing inner ring to 100-120°C, place
it on the differential housing journal, and fit it in
place.
2. Mount the differential assembly.

assembly.

assembly.
Replacement of differential bearing 77

XVII. Replacement of axle shaft gear, planetary gear and cross axle
Tools and auxiliary

Name and model
materials
Common tools Sleeves S21/S27/S30/S34/S36, final drive jack, bearing puller, pneumatic
Testing tools Torque wrench （110~850N·m）, magnetic stand and dial gauge, spring
balance (0-150N), external micrometer, internal gauge

Removal

assembly.

assembly.
assembly.
78 Replacement of axle shaft gear, planetary gear and cross axle

3. Remove the differential right housing.

1). Remove those 12 bolts used to fix differential
left and right housings.
2). Use the copper bar to lightly knock the
differential housing surface, and remove the
differential right housing.
4. Remove the right axle shaft gear and

supporting washer.
1). Remove the right axle shaft gear and
supporting washer from the planetary gear and
cross axle.
5. Check the backlash of planetary gear.

1). Hold the cross axle and differential housing,
and use the dial gauge to measure backlash of
planetary gear.
Notice: If the measured backlash doesn’t

conform to relevant requirements, replace the
axle shaft gear and planetary gear supporting
washer.
6. Remove the planetary gear and cross axle.

1). Remove the planetary gear and cross axle from
the differential left housing.
Replacement of axle shaft gear, planetary gear and cross axle 79

7. Dismount the planetary gear and cross axle.

1). Dismantle these 4 planetary gears, 4
supporting washers and 1 cross axle.
8. Remove the left axle shaft gear and

supporting washer.
1). Remove the left axle shaft gear and supporting
washer from the left differential housing.
Inspections
2. Check the wear conditions of axle shaft gear,
planetary gear and cross axle.
Notice: If seriously worn, replace them.
3. Check the fit clearance between planetary
gear and cross axle.
1). Measure the internal diameter of planetary gear
and external diameter of cross axle journal, and
Fit clearance = Internal diameter of planetary gear
– external diameter of cross axle journal.
Standard size 0.065~0.119mm
Wear limit 0.30mm
Notice: If the fit clearance exceeds the wear

limit, make replacement.

4. Check the fit clearance between axle shaft

gear and differential housing.
1). Measure the external diameter of axle shaft
gear spline shaft and internal diameter of
differential housing, and calculate their fit
clearance.
Fit clearance =Internal diameter of differential
housing – External diameter of axle shaft gear
spline shaft
Wear limit 0.60mm

Mounting
1. Mount the left axle shaft gear and supporting
washer.
1). Fit the left axle shaft gear and supporting
washer into the differential left housing.
2. Assemble the planetary gear and cross axle.

1). Assemble those 4 planetary gears, 4 supporting
washers and 1 Cross axle.
3. Mount the planetary gear and cross axle.

2). Fit the planetary gear and cross axle into the
differential left housing.

3). Check the backlash of planetary gear.

and use a dial gauge to measure the backlash of
planetary gear.

washer.
4. Mount the right axle shaft gear and

supporting washer.
1). Place the right axle shaft gear and supporting
washer onto the planetary gear and cross axle.
2). Apply engine oil onto the meshing parts of the
gear, and ensure the smooth rotation of gears.
5. Mount the differential right housing.

1). Align mounting marks on differential left and
right housings.
2). Apply sealant onto left and right differential

housing lock bolts, screw in 2-3 threads, and use
the pneumatic spanner to tighten these 12 bolts
crosswise.

3). Insert the differential spanner into the axle shaft

gear spline hole, and check the performance of
differential.
Notice: Ensure free rotation without seizure.

assembly.
assembly.


XVIII. Replacement of differential housing

Tools and auxiliary

Name and model
materials

Common tools
Torque wrench（110~850N·m）, magnetic stand and dial gauge, spring

Testing tools

Removal

assembly.

assembly.
assembly.
84 Replacement of differential housing



supporting washer.
cross axle.

planetary gear.

washer.

Replacement of differential housing 85


supporting washer.

gear.
impacts.

3). Remove differential left and right housings.

Inspection
1. Clean removed parts.
2. Check whether the differential housing is
damaged.
1). Carefully check whether differential left and
right housing surfaces are cracked or worn; if
necessary, make replacement.
Notice: Differential left and right housings shall
be replaced in pairs.
clearance.
spline shaft
Wear limit 0.60mm
Mounting
1). Heat the bearing inner ring to 100-120°C, then
place it on the differential housing journal, and fit it
in place.




washer.
4. Mount planetary gear and cross axle.

2).Check the backlash of planetary gear.

planetary gear.

washer.

supporting washer.


right housings.

crosswise.

differential.
Notice: Ensure free rotation without seizure

assembly.
assembly.



XIX. Repair of differential assembly

Tools and auxiliary

Name and model
materials

Common tools

Testing tools

Removal

assembly.

assembly.
assembly.
Repair of differential assembly 91

Disassembly

supporting washer.
cross axle.

planetary gear.

washer.

92 Repair of differential assembly



supporting washer.

gear.
impacts.


Inspection
Wear limit 0.30mm


clearance.
spline shaft
Wear limit 0.60mm

Mounting
place.




washer.
4. Assemble planetary gear and cross axle.

1). Assemble these 4 planetary gears, 4 supporting
washers and 1 cross axle.



planetary gear.

washer.

supporting washer.

right housings.

crosswise.


differential.
Mounting
assembly.
assembly.


XX. Replacement of final drive housing

Tools and auxiliary

Name and model
materials

Common tools
copper bar, iron hammer

Testing tools
balance (0-150N)

Removal

assembly.

cone gears.
results.
98 Replacement of final drive housing

3. Remove the locking plate.

1). Remove the differential bearing cover locking
plate.
4. Remove the differential bearing adjusting

nut.
1). Undo the bearing cover lock bolt.
2). Use the differential spanner to remove the
differential bearing adjusting nut.
5. Remove the differential bearing cover.

1). Mark mounting marks on the differential bearing
cover and final drive housing.
2). Remove bearing cover bolts on sides.
3). Remove the differential bearing cover.

Notice: Bearing covers shall be placed on both
sides to avoid confusion.
Replacement of driving bevel gear rear bearing 99


assembly.
1). Hoist the differential & driven cone gear
assembly out of the final drive housing.
7. Remove the final drive housing.

1). Remove those 8 bolts of final drive housing
used to fix the bearing seat.
2). Use the remover to remove the driving bevel
gear and bearing seat & flange assembly.
Notice: Never use the copper bar or hammer to
knock the flange.
3). Remove the O-shaped ring and driving bevel
gear adjusting shim.
4). Remove the final drive housing.
Inspection
1. Check the final drive housing.
1). Check the final drive housing bears damages or
cracks; if any, replace the housing.
2. Check the differential bearing cover.
1). Check whether the differential bearing inner
surface is worn; if any, make replacement.
Notice: The final drive housing and differential
bearing cover shall be replaced in pairs.

Mounting
1. Mount the final drive housing.
1). Fit one new O-shaped ring and one group of
driving bevel gear adjusting shims onto the bearing
seat.
2). Fit the driving bevel gear and bearing seat &
flange assembly into the final drive housing.
3). Tighten these 8 lock bolts.

assembly.
1). Fit the differential & driven cone gear assembly
into the final drive housing.
3. Mount the differential bearing cover.

1). Apply lubricating oil onto the bearing roller
evenly.
2). Fit the differential bearing adjusting nut.
Notice: The differential housing, adjusting nut
and bearing cover are provided with the same
thread pitches.
3). Align the bearing cover mounting marks, and
use 2 bolts to fit the differential bearing cover.
Notice: Do not tighten the bolt now.
cone gears

5). Adjust the differential adjusting nut equally till the required driven gear backlash is obtained.

bearing.
Standard starting force 80~120N
6. Adjust the mesh marks of driving and driven

cone gears.
1). Paint at least 4 teeth equally spaced on the
upper edge of driven cone gear, slightly rotate the
cone gear, and check the mesh of the gear under Along tooth line direction Along tooth line direction
minor load.
Notice: Under minor load, the correct mesh
marks of driving and driven cone gears shall
Gearwheel convex face Gearwheel concave face
meet requirements shown in the figure below.
The mesh mark in the tooth length direction
shall slightly deviate to the smaller end, and
the tooth height direction shall be located at
the tooth middle or slightly deviate to the tooth
crest, with the length accounting for about 60%
of the tooth face width and the height about
1.5mm far from the tooth crest.
If the gear mesh mark can’t meet above-mentioned requirements, readjust the gear as per the
method described below till relevant requirements are met.

No. Gear contact zone Results of test Adjusting method
The contact
1 No adjustment is required
zone is proper
The driving and

driven cone
Loosen the left
gears are too
2 nut, and tighten
close to each
the right one.
other, with small
backlash.
The driving and

driven cone
Loosen the right
gears are too far
3 nut, and tighten
from each other,
the left one.
with large
backlash.
The driven cone

gear mesh zone
is too high, and Reduce the
4 the driving and thickness of
driven cone adjusting shims.
gears are too far
from each other.
The driven cone

gear mesh zone
is too low, and
Increase the
the driving and
5 thickness of
driven cone
adjusting shims.
gears are too
close from each
other.

7. Fit the locking plate.

1). Fit the differential bearing cover locking plate.



XXI. Replacement of driving bevel gear rear bearing

Tools and auxiliary

Name and model
materials

Common tools

Testing tools
balance (0-150N)

Removal

assembly.
2. Remove the final differential housing.

Refer to the replacement of final drive housing.

3. Remove the driving bevel gear rear bearing.

1). Remove the spring collar for shaft.
2). Use the bearing puller to remove the driving
bevel gear rear bearing.
3). Remove the bearing inner ring.
Mounting
1. Mount the driving bevel gear rear bearing.
1). Press and mount the driving bevel gear rear
bearing into the driving bevel gear.
2). Mount the Spring collar for shaft.


assembly.
106 Replacement of driving bevel gear rear bearing

XXII. Replacement of driving bevel gear bearing seat

Tools and auxiliary

Name and model
materials

Common tools
copper bar, iron hammer, bearing puller

Testing tools
balance (0-150N)

Removal

assembly.

Replacement of driving bevel gear bearing seat 107


1). Remove the driving bevel gear nut and washer.
2). Remove the flange from the driving bevel gear
and bearing seat.
gear oil seal from the driving bevel gear bearing
seat.
5. Remove the driving bevel gear bearing seat.

1). Press the driving bevel gear bearing seat and
front external bearing inner ring out of the driving
bevel gear.
2). Remove the bearing outer ring.
3). Remove the driving bevel gear bearing seat.
Mounting
1. Mount the driving bevel gear bearing seat.
1). Press the driving bevel gear bearing outer ring
into the bearing seat.
2). Fit the driving bevel gear onto the bearing seat.
3). Mount the external bearing inner ring by press
fit.
2. Mount the driving bevel gear oil seal

1). Clean the oil seal mounting hole on the driving
bevel gear bearing seat inner wall.
hole, and ensure that the oil seal external surface
is flush with the bearing seat plane.
108 Replacement of driving bevel gear bearing seat


2). Fit the washer and driving bevel gear nut.


assembly.
Replacement of driving bevel gear bearing seat 109

XXIII. Replacement of driving bevel gear front bearing

Tools and auxiliary

Name and model
materials

Common tools
copper bar, iron hammer, bearing puller, pressing machine

Testing tools
balance (0~10N/0~150N)

Removal

assembly.

110 Replacement of driving bevel gear front bearing


and bearing seat.
seat.
5. Remove the driving bevel gear bearing seat.

bevel gear.
2).Remove the driving bevel gear bearing seat.
3). Remove the adjusting washer and bearing

bush.
4). Remove the driving bevel gear front inner

bearing inner ring.
5). Remove these 2 bearing outer rings from the
driving bevel gear bearing seat.
Replacement of driving bevel gear front bearing 111

Mounting
1. Mount the driving bevel gear bearing seat.

1). Press two driving bevel gear front bearing outer
rings into the bearing seat.
2). Press the driving bevel gear front inner bearing

inner ring onto the driving bevel gear.
3). Mount the adjusting shim and bearing bush.
fit.

2. Check the pre-tightening force of driving

bevel gear bearing.
1). Fit the flange and washer, and tighten the
driving cone nut.
2). Fix the bearing seat on the bench clamp, and

use one end of the spring balance to hook the
flange bolt hole to measure the starting force.
Notice: If the measured starting force is not

within the specified range, it is necessary to
adjust the washer thickness and then re-check
the pre-tightening force.
3). After the pre-tightening force is adjusted, remove the driving cone nut, washer and flange.


Replacement of driving bevel gear front bearing 113



assembly.

XXIV. Replacement of driving and driven cone gears

Tools and auxiliary

Name and model
materials

Common tools
copper bar, iron hammer, bearing puller, pressing machine

Testing tools

Removal

assembly.

cone gears.
results.
Replacement of driving and driven cone gears 115


assembly.
assembly.

knock the flange.

and bearing seat.
seat.
7. Remove the driving bevel gear.

bevel gear.
116 Replacement of driving and driven cone gears

3). Remove the adjusting shim and bearing bush.
4). Remove the driving bevel gear inner bearing

inner ring.
5). Remove 2 bearing outer rings from the driving
bevel gear bearing seat.
6). Remove the driving bevel gear.

gear.
impacts.
Inspection
2. Check the driving and driven cone gears.
1). Check whether the meshing part of driving and driven cone gears is worn.
2). Check the degree of wear of driving bevel gear journal.
3). Check the mating surface between driven cone gear and differential housing.
Notice: If seriously worn, the driving and driven cone gears shall be replaced in pairs.

Mounting

2. Mount the driving bevel gear.

1). Press these 2 driving bevel gear front bearing
outer rings into the bearing seat.

3). Mount the adjusting washer and bearing bush.

5). Press fit the driving bevel gear front external
bearing inner ring.

bevel gear bearing.
driving cone nut.






seat.

assembly.
assembly.

cone gears.


5). Adjust the differential adjusting nut equally till the required driven gear backlash is obtained.

bearing.
10. Adjust the mesh marks of driving and

driven cone gears.
Along tooth line direction
cone gear, and check the mesh of the gear under Along tooth line direction
minor load..
marks of driving and driven cone gears shall
Gearwheel convex face Gearwheel concave face
If the gear mesh mark can’t meet above-mentioned requirements, readjust the gear as per the method
described below till relevant requirements are met.

The contact
zone is proper
The driving and

driven cone
Loosen the left
gears are too
2 nut, and tighten
close to each
the right one.
other, with small
backlash.
The driving and

driven cone
Loosen the right
gears are too far
3 nut, and tighten
from each other,
the left one.
with large
backlash.
The driven cone

gear mesh zone
gears are too far
from each other.
The driven cone

gear mesh zone
is too low, and
Increase the
the driving and
5 thickness of
driven cone
adjusting shims.
gears are too
close from each
other.

3).Fit the locking plate.



XXV. Repair of final drive assembly

Tools and auxiliary

Name and model
materials

Common tools
spanner, copper bar, iron hammer, bearing puller, pressing machine

Testing tools

Removal

assembly.

assembly.
assembly.
124 Repair of final drive assembly

3. Remove the final differential housing.

knock the flange.
Disassembly of driving cone assembly

and bearing seat.
seat.
3. Remove the driving bevel gear.

bevel gear.
3). Remove the adjusting washer and bearing

bush.
Repair of final drive assembly 125

4). Remove the driving bevel gear front inner

bearing inner ring.
5). Remove these 2 bearing outer rings from the
driving bevel gear bearing seat.
6). Remove the driving bevel gear.
Disassembly of differential housing


supporting washer.
cross axle.

planetary gear.

washer.




supporting washer.

gear.
impacts.


Inspection
Wear limit 0.30mm
clearance.
spline shaft
Wear limit 0.60mm
5. Check the driving and driven cone gears.
1). Check whether the meshing part of driving and driven cone gears is worn.
2). Check the degree of wear of driving bevel gear journal.
3). Check the mating surface between driven cone gear and differential housing.
Notice: If seriously worn, the driving and driven cone gears shall be replaced in pairs.

6. Check the final drive housing.

1). Check the final drive housing bears damages or
cracks; if any, replace the housing.
7. Check the differential bearing cover.
1). Check whether the differential bearing inner
surface is worn; if any, make replacement.
Notice: The final drive housing and differential
bearing cover shall be replaced in pairs.
Reassembly of differential assembly

place.



washer.


1). Reassemble these 4 planetary gears, 4


planetary gear.

washer.

supporting washer.


right housings.

crosswise.

differential.
Assembly of driving cone assembly

1. Mount the driving bevel gear.
1). Press two driving bevel gear front bearing outer
rings into the bearing seat.


3). Mount the adjusting shim and bearing bush.
fit.

bevel gear bearing.
driving cone nut.



Mounting
seat.

assembly.
assembly.


cone gears.
5). Adjust the differential adjusting nut equally till
the required driven gear backlash is obtained.
bearing.
5. Adjust the mesh marks of driving and driven

cone gears.
Along tooth line direction
cone gear, and check the mesh of the gear under Along tooth line direction
minor load..
marks of driving and driven cone gears shall Gearwheel convex face Gearwheel concave face

If the gear mesh mark can’t meet above-mentioned requirements, readjust the gear as per the method
described below till relevant requirements are met.
The contact
zone is proper
The driving and

driven cone
Loosen the left
gears are too
2 nut, and tighten
close to each
the right one.
other, with small
backlash.
The driving and

driven cone
Loosen the right
gears are too far
3 nut, and tighten
from each other,
the left one.
with large
backlash.
The driven cone

gear mesh zone
gears are too far
from each other.
The driven cone

gear mesh zone
is too low, and
Increase the
the driving and
5 thickness of
driven cone
adjusting shims.
gears are too
close from each
other.

3).Fit the locking plate.



XXVI. Replacement of thrust bar assembly

Tools and auxiliary

Name and model
materials
Common tools Sleeve S27, double offset ring spanner, copper bar
Auxiliary materials ——
Removal
1. Remove the thrust bar assembly.
1). Remove 2 bolts used to fix the thrust bar assembly from the rear axle bracket.
2). Remove 2 bolts sued to fix the thrust bar assembly from the bracket on the frame.
3). Remove the thrust bar assembly.
Mounting
1. Mount the thrust bar assembly.
1). Use 2 bolts to connect the thrust bar assembly onto the rear axle bracket.
2). Use 2 bolts to connect the thrust bar assembly onto the bracket on the frame.
3). Fasten these 4 bolts.
Replacement of thrust bar assembly 137

XXVII. Removal and mounting of rear axle assembly

Tools and auxiliary

Name and model
materials
Sleeves S21/S27, double offset ring spanner S21, open-end spanner S21,
Common tools
rear axle carrier, copper bar, pry bar, jack, split heads

On-board inspection
1. Check the total clearance of driving axle.

1). Apply the hand control valve, and prevent the
driving bevel gear from rotating.
2). Pry up the rear axle on one side.
3). Move the pointer to the rim edge.

4). Rotate the wheel to one side to the limit
position, and make a mark at the pointer position.
Thereafter, rotate the wheel to another side to the
limit position, and make another mark. The
distance between both extreme points will
indirectly reflect the total clearance between
driving gears.
Limit size 45mm
Notice: If the distance between both limit points

is more than 45mm, it is necessary to check
the fit clearance between various parts of the
rear axle, and if necessary, the adjustment can
be made.
138 Removal and mountmounting of rear axle assembly

Removal
1. Separate the drive shaft.
fork and the final reducer flange connected to it.
2). Remove these 4 nuts between flange and drive
shaft, and disconnect the drive shaft from rear
axle.
2. Remove the rear axle transverse stabilizer
bar.
stabilizer bar.
3. Jack the frame.

1). Use 2 jacks to support the frame.
4. Remove the left and right rear wheels. Refer
to the removal and mounting of rear wheel
assembly.
5. Remove left and right rear wheel mudguards.
Refer to the replacement of wheel mudguard.
6. Remove the rear axle thrust bar assembly.

Refer to the replacement of thrust bar assembly.
7. Disconnect the connector of rear axle ABS

Front
sensor wiring harness.
Bracket on the carling

1). Disconnect two rear axle ABS sensor wire
connectors.
8. Separate the height sensor adjusting rod.
1). Remove 2 bolts.
2) Separate the height sensor adjusting rod from Bracket on rear axle
the rear axle housing.
9. Disconnect left and right brake chamber

nylon pipes.
1). Disconnect these 4 brake chamber pipelines.
Removal and mountmounting of rear axle assembly 139

10. Separate the brake pipeline bracket.

1). Remove these 2 nuts.
2). Separate the brake pipeline bracket from the
rear axle housing.
11. Remove left and right rear shock absorbers.
Refer to the replacement of shock absorber
assembly.
12. Remove left and right U-shaped bolts.
13. Pull out the rear axle assembly.

1). Pull the rear axle assembly from the
underframe using the rear axle carrier.
Notice: The rear axle assembly must be placed
stably to prevent slip-out.
Mounting
1. Pull the rear axle assembly into beneath the
underframe.
Notice: The rear axle assembly must be placed
stably to prevent slip-out.
2. Mount left and right U-shaped bolts.
Refer to the replacement of U-shaped bolts.
3. Mount the brake pipeline bracket.

1). Use 2 nuts to fit the brake pipeline bracket onto
the final driving housing.

4. Connect left and right brake chamber nylon

pipes.
1). Connect brake pipeline.
2). Tighten the bolt on the brake chamber.
5. Mount the height sensor adjusting rod.

1). Use 2 bolts to fit the height sensor adjusting rod
onto the rear axle housing.
6. Connect the rear axle ABS sensor wiring
harness connector.
1). Connect two rear axle ABS sensor wire
connectors.
7. Mount the rear axle thrust bar assembly.
Bracket on the side member

Refer to the replacement of thrust bar assembly.
Front
8. Mount the left and right rear wheel
mudguards.
Refer to the replacement of wheel mudguards.
9. Mount left and right rear wheels.
assembly. Bracket on the rear
axle
10. Mount left and right rear wheels.
assembly.
11. Lower the frame.

1). Lower the jack and split heads.
2). Stably lower the frame and land wheels.
12. Mount the rear axle transverse stabilizer
bar.
stabilizer bar.
Removal and mountmounting of rear axle assembly 141


1). Align mating marks, and use 4 nuts to connect
the drive shaft and final drive flange.

XXVIII. Replacement of rear axle housing assembly

Tools and auxiliary

Name and model
materials
Sleeves S21/S27, double offset ring spanner S21, open-end spanner

Common tools S21, rear axle carrier, phillips screwdriver, copper bar, pry bar, jack, split
heads
Special tools
sleeve hub bearing remover, hub puller,
Testing tools Torque wrench (0~600N·m）
Auxiliary materials Triangular wooden block, sealant, gasoline, oil basin

Removal
1. Fully discharge the rear axle gear oil.

1). Remove the oil drain plug to fully discharge the
rear axle gear oil.
2. Remove the rear axle assembly.
Refer to the removal and mounting of rear axle
assembly.
3. Remove left and right axle shafts.

Refer to the replacement of rear axle shafts.
Replacement of rear axle housing assembly 143

4. Remove left and right wheel hub brake drum

assemblies.
Refer to the replacement of rear hub bearing.
5. Remove left and right rear brake assemblies.

1). Remove 4 bolts used to fix the brake chamber.
2). Remove 12 bolts on the brake bottom plate.
3). Remove the brake assembly from the rear axle.

1). Remove these 10 bolts and 2 nuts.
2). Use the hoisting device to hoist the final drive
assembly from the rear axle housing.
144 Replacement of rear axle housing assembly

7. Remove the rear axle housing.

1). Remove the vent plug.
2). Remove the drain plug.
3). Remove the oil level plug.
4). Remove four studs.
5). Remove the rear axle housing.
Inspection 1. Vent plug 5. Drain plug

1. Check whether there is any crack on the rear 2. Sealing gasket 6. Washer
axle housing.
3. Oil level plug 7. Stud
1). Visually check whether there is any crack on
4. Rear axle housing
the rear axle housing.
Notice: If there is any crack, replace the
housing.
2. Check whether the rear axle housing is deformed.

1). Thread a wire through the rear axle housing.
2). Suspend loads onto both ends of the wire to straighten it.
3). Visually check whether the wire fits against the axle housing inner wall.
4). Rotate the rear axle housing by 45°, and visually check whether the wire fits against the axle housing
inner wall.
Notice: If the rear axle housing is seriously deformed, replace it.
Mounting
1. Mount the rear axle housing.
1). Place the rear axle housing on the bracket.
2). Fit the vent plug.
3). Fit the drain plug.
4). Fit the oil level plug.
5). Fit these 4 studs.
1. Vent plug 5. Drain plug

2. Sealing gasket 6. Washer
3. Oil level plug 7. Stud
4. Rear axle housing


1). Use the flat shovel to remove residual sealant
on the mating face between reducer and axle
housing.
2). Apply new sealant onto the mating surface
between reducer and axle housing and onto the
fastening bolts.
3). Use the hoisting device to fit the final drive

assembly into the axle housing.
4). Fit these 10 bolts and 2 nuts.
3. Mount left and right rear brake assemblies.

1). Fit the brake assembly into the rear axle.
2). Use 4 bolts to fix the brake chamber bracket
onto the rear axle housing.
3). Tighten these 12 bolts on the brake bottom

plate.
4. Mount left and right hub brake drum

assemblies.
Refer to the replacement of rear hub bearing.

5. Mount left and right axle shafts.

Refer to the replacement of rear axle shaft.
6. Mount the rear axle assembly.

Refer to the removal and mounting of rear axle
assembly.
7. Fill rear axle gear oil.

1). Remove the filler plug, and refill rear axle gear
oil.
Filling quantity 14L of 85W/90GL-5

heavy-duty
automobile gear oil
2). Tighten the drain plug.
1. Filler plug 2. Drain plug


dongfeng 460 13T rear axle 中后桥维修手册-en

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dongfeng 460 13T rear axle 中后桥维修手册-en

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Service Manual for Dongfeng 460 Series Central & Rear Axle

Rear axle assembly

Central axle final drive

Rear axle final drive

(II) Technical parameters

Item Major parameter

Major adjustment data

Adjustment item Adjustment data

Gear backlash 0.30～0.40mm

Nominal Service Wear

Nominal Service Repair Wear

(III) Tightening torque

Part to be tightened Tightening torque (N·m)

Item Tightening torque (N.m)

Part Tightening torque (N.m)

(IV) Fault diagnosis

Fault diagnosis of self-adjusting arm

II. Removal and mounting of central axle final drive assembly

Tools and auxiliary

Common tools Sleeve S27, copper bar, flat shovel

auxiliary materials Triangular wooden block, lubricating grease

(II) Working procedure

1. Use the triangular wooden block to hold

2. Fully discharge the gear oil.

3. Remove the drive shaft

Removal and mounting of central axle final drive assembly 11

6. Remove the axle shaft.

7. Remove the final drive assembly

2. Use a horizontal pulley type final drive jack

1. Outer side 2. Inner side 3. Bolt hole

12 Removal and mounting of central axle final drive assembly

3. Mount the axle shaft.

8. Refill the gear oil.

Removal and mounting of central axle final drive assembly 13

III. Replacement of central axle driving and driven gear assembly

14 Repair of central axle inter-axle differential assembly

(I) Recommended tools and auxiliary materials

Tools and auxiliary

Auxiliary materials Triangular wooden block, grease

(II) Working procedure

1. Remove the final drive assembly.

2. Remove the inter-axle differential assembly.

3. Remove the inter-axle differential control

Repair of central axle inter-axle differential assembly 15

5. Measure and record the backlash between

6. Remove the final drive housing assembly.

16 Repair of central axle inter-axle differential assembly

8. Measure and record the backlash of driven

9. Remove the locking plate.

10. Make a rectification mark on the bearing

11. Remove the adjusting nut

Repair of central axle inter-axle differential assembly 17

12. Remove the bolt and bearing cover.

13. Remove the final drive assembly.

14. Remove the transmission gear.

1. Puller bolt hole

15. Remove the engine oil collector and

1. Engine oil collector

18 Repair of central axle inter-axle differential assembly

16. Remove the driving bevel gear

2). Press out the driving bevel gear, and remove

3). Use a bearing puller to remove the hoop and

4) Use the bearing puller to remove the cone roller

Repair of central axle inter-axle differential assembly 19