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Service Manual Axle 114 ASM-0006E July 2015 CONTENTS INTRODUCTION ................................................................................................................................ 5 SPECIFICATIONS .............................................................................................................................. 7 DEFINITION OF VIEWPOINTS ...................................................................................................................... 7 DATA PLATE ................................................................................................................................................. 7 CONVERSION TABLES ................................................................................................................................ 8 UNITS OF PRESSURE ............................................................................................................................. 8 UNIT OF WEIGHT .................................................................................................................................... 8 UNITS OF TORQUE ................................................................................................................................. 8 TORQUE SPECIFICATIONS ......................................................................................................................... 9 COARSE PITCH ....................................................................................................................................... 9 FINE PITCH .............................................................................................................................................. 9 WHEEL NUT TIGHTENING TORQUES .................................................................................................... 10 MAINTENANCE ................................................................................................................................. 11 MAINTENANCE POINTS .............................................................................................................................. 11 AXLE MODEL WITH SERVICE BRAKE AND NEGATIVE PARKING BRAKE ........................................... 11 AXLE MODEL WITH SERVICE BRAKE .................................................................................................... 12 OIL DRAINING MANDATORY PROCEDURE ................................................................................................ 13 CENTRAL HOUSING ............................................................................................................................... 13 PLANETARY GEAR REDUCTION ............................................................................................................ 13 MAINTENANCE INTERVALS ........................................................................................................................ 14 LUBRICANT & SEALANT SPECIFICATIONS ................................................................................................ 15 SAFETY PRECAUTIONS ................................................................................................................... 17 PLANETARY REDUCTION ................................................................................................................ 19 EXPLODED VIEW .......................................................................................................................................... 19 DISASSEMBLY ............................................................................................................................................. 20 ASSEMBLY ................................................................................................................................................... 24 SPECIAL TOOLS .......................................................................................................................................... 29 T1 ............................................................................................................................................................. 29 T2 ............................................................................................................................................................. 30 T3 ............................................................................................................................................................. 31 T4 ............................................................................................................................................................. 32 SERVICE BRAKE ............................................................................................................................... 33 EXPLODED VIEW .......................................................................................................................................... 33 DISASSEMBLY ............................................................................................................................................. 34 ASSEMBLY ................................................................................................................................................... 36 SERVICE BRAKE AND NEGATIVE PARKING BRAKE .................................................................... 39 EXPLODED VIEW .......................................................................................................................................... 39 RELEASE ...................................................................................................................................................... 40 ADJUSTMENT .............................................................................................................................................. 40 DISASSEMBLY ............................................................................................................................................. 41 ASSEMBLY ................................................................................................................................................... 45 DIFFERENTIAL .................................................................................................................................. 51 EXPLODED VIEW .......................................................................................................................................... 51 DISASSEMBLY ............................................................................................................................................. 52 ASSEMBLY ................................................................................................................................................... 55 SPECIAL TOOLS .......................................................................................................................................... 61 T1 ............................................................................................................................................................. 61 T2 ............................................................................................................................................................. 62 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 3 BEVEL PINION ................................................................................................................................... 63 EXPLODED VIEW .......................................................................................................................................... 63 DISASSEMBLY ............................................................................................................................................. 64 ASSEMBLY ................................................................................................................................................... 67 SEAL RING REPLACEMENT ........................................................................................................................ 72 DISASSEMBLY ........................................................................................................................................ 72 ASSEMBLY .............................................................................................................................................. 72 SPECIAL TOOLS .......................................................................................................................................... 73 T1 ............................................................................................................................................................. 73 T2 ............................................................................................................................................................. 74 T3 ............................................................................................................................................................. 76 T4 ............................................................................................................................................................. 77 T5 ............................................................................................................................................................. 78 T6 ............................................................................................................................................................. 79 T7 ............................................................................................................................................................. 80 4 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual INTRODUCTION The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the operations, allows accurate work to be performed.All the information needed for correct disassembly, checks and assembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle. IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any encrusted or accumulated grease. INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly check the condition of all moving parts (bearings, gears, ring gear and pinion, shafts) and sealing parts (o-rings, oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge. In the case of the ring gear and pinion, replacement of one component requires the replacement of the other one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained. SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorized Distributors of Dana Holding. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 5 6 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIFICATIONS DEFINITION OF VIEWPOINTS RIGHT SIDE LATO DESTRO RECHTE SEITE LADO DERECHO COTE DROITE LEFT SIDE LATO SINISTRO LINKE SEITE LADO IZQUIERDO COTE GAUCHE DATA PLATE R 2 1 3 MFG. BY DANA ITALIA S.P.A. 38062 Arco (Trento) MADE IN ITALY 1 - Type and model unit - modification index 2 - Serial number 3 - Lubricant ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 7 CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE Atm Bar MPa Pa PSI Atm 1 1 0,1 105 14,4 Bar 1 1 0,1 105 14,4 MPa 10 10 1 106 144 Pa 0,00001 0,00001 10-6 1 - PSI - - - - 1 N daN kN kg lbs UNIT OF WEIGHT 1N 1 0,1 0,001 0,102 0,225 1daN 10 1 0,01 1,02 2,25 1kN 1000 100 1 102 225 1kg 9,81 0,981 0,00981 1 2,205 UNITS OF TORQUE N·m daN·m kN·m kg·m lb·in 1N·m 1 0,1 0,001 0,102 8,854 1daN·m 10 1 0,01 1,02 88,54 1kN·m 1000 100 1 102 8854 1kg·m 9,81 0,981 0,00981 1 86,8 1 lb·in 0,1129 0,01129 0,0001129 0,01152 1 8 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT 8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270 M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m M12 x 1,75 mm 82 – 91 N·m 90 – 100 N·m 116 – 128 N·m 126 – 139 N·m 139 – 153 N·m 152 – 168 N·m M14 x 2 mm 129 – 143 N·m 143 – 158 N·m 182 – 202 N·m 200 – 221 N·m 221 – 244 N·m 238 – 263 N·m M16 x 2 mm 200 – 221 N·m 219 – 242 N·m 283 – 312 N·m 309 – 341 N·m 337 – 373 N·m 371 – 410 N·m M18 x 2,5 mm 276 – 305 N·m 299 – 331 N·m 390 – 431 N·m 428 – 473 N·m 466 – 515 N·m 509 – 562 N·m M20 x 2,5 mm 390 – 431 N·m 428 – 473 N·m 553 – 611 N·m 603 – 667 N·m 660 – 730 N·m 722 – 798 N·m M22 x 2,5 mm 523 – 578 N·m 575 – 635 N·m 746 – 824 N·m 817 – 903 N·m 893 – 987 N·m 974 – 1076 N·m M24 x 3 mm 675 – 746 N·m 732 – 809 N·m 950 – 1050 N·m 1040 – 1150 N·m 1140 – 1260 N·m 1240 – 1370 N·m M27 x 3 mm 998 – 1103 N·m 1088 – 1202 N·m 1411 – 1559 N·m 1539 – 1701 N·m 1710 – 1890 N·m 1838 – 2032 N·m M30 x 3,5 mm 1378 – 1523 N·m 1473 – 1628 N·m 1914 – 2115 N·m 2085 – 2305 N·m 2280 – 2520 N·m 2494 – 2757 N·m FINE PITCH SIZE OF BOLT TYPE OF BOLT 8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270 M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m M12 x 1,25 mm 90 – 100 N·m 98 – 109 N·m 128 – 142 N·m 139 – 154 N·m 152 – 168 N·m 166 – 184 N·m M12 x 1,5 mm 86 – 95 N·m 94 – 104 N·m 120 – 132 N·m 133 – 147 N·m 143 – 158 N·m 159 – 175 N·m M14 x 1,5 mm 143 – 158 N·m 157 – 173 N·m 200 – 222 N·m 219 – 242 N·m 238 – 263 N·m 261 – 289 N·m M16 x 1,5 mm 214 – 236 N·m 233 – 257 N·m 302 – 334 N·m 333 – 368 N·m 361 – 399 N·m 394 – 436 N·m M18 x 1,5 mm 312 – 345 N·m 342 – 378 N·m 442 – 489 N·m 485 – 536 N·m 527 – 583 N·m 580 – 641 N·m M20 x 1,5 mm 437 – 483 N·m 475 – 525 N·m 613 – 677 N·m 674 – 745 N·m 736 – 814 N·m 808 – 893 N·m M22 x 1,5 mm 581 – 642 N·m 637 – 704 N·m 822 – 908 N·m 903 – 998 N·m 998 – 1103 N·m 1078 – 1191 N·m M24 x 2 mm 741 – 819 N·m 808 – 893 N·m 1045 – 1155 N·m 1140 – 1260 N·m 1235 – 1365 N·m 1363 – 1507 N·m M27 x 2 mm 1083 – 1197 N·m 1178 – 1302 N·m 1520 – 1680 N·m 1672 – 1848 N·m 1834 – 2027 N·m 2000 – 2210 N·m M30 x 2 mm 1511 – 1670 N·m 1648 – 1822 N·m 2138 – 2363 N·m 2332 – 2577 N·m 2565 – 2835 N·m 2788 – 3082 N·m ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 9 TORQUE SPECIFICATIONS WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended from rim's O.E.M. with reference to the quality of the rim's material. WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY ST 37 WHEEL NUTS WITH INTEGRATED SPHERICAL COLLAR FLAT COLLAR WHEEL NUTS WITH SEPARATE SPHERICAL LOCK WASHER WHEEL NUTS WITH INTEGRATE SEAT CAPTIVE WASHER **ST 52 M18X1,5 mm 330 N·m 460 N·m M20X1,5 mm 490 N·m 630 N·m M22X1,5 mm 630 N·m 740 N·m M18X1,5 mm 270 N·m 360 N·m M20X1,5 mm 360 N·m 450 N·m M22X1,5 mm 460 N·m 550 N·m M18X1,5 mm 260 N·m 360 N·m M20X1,5 mm 350 N·m 500 N·m M22X1,5 mm 450 N·m 650 N·m **RIM'S MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS. IT IS THE OPTIMUM MATERIAL FOR TIGHTENING THE RIM TO THE HUB. NOTE: The wheel nut tightening torque is related only on nut thread and stud thread dry. (Without oil or any lubricant). NOTE: The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of the rim material. THE DANA OFFICIAL TIGHTENING TORQUE TABLE, THAT IS INCLUDED IN EACH SERVICE MANUAL, SHOWS THE TORQUE FIGURE RELATED TO THE BOLT CHARACTERISTIC ONLY. DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8.8 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE M18 x 1,5 mm M18 x 1,5 N·m 442 - 489 N·m M20 x 1,5 mm M20 x 1,5 N·m 613 - 677 N·m M22 x 1,5 mm M22 x 1,5 N·m 822 - 908 N·m *THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY (DANA AXLES ARE 10.9 ONLY). 10 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual MAINTENANCE MAINTENANCE POINTS AXLE MODEL WITH SERVICE BRAKE AND NEGATIVE PARKING BRAKE 1 1 3 3 2 4 4 5 1 P1 B2 B1 2 3 P2 1 - Oil filling plug P1 - Connector for negative brake 2 - Oil draining plug P2 - Connector for hydraulic service brake 3 - Check level plug B1 - Bleeding screw for negative brake 4 - Release screw for negative brake B2 - Bleeding screw for hydraulic service brake 5 - Breather ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 11 MAINTENANCE POINTS AXLE MODEL WITH SERVICE BRAKE 1 1 3 3 2 2 4 1 P2 2 3 B2 1 - Oil filling plug P2 - Connector for hydraulic service brake 2 - Oil draining plug B2 - Bleeding screw for hydraulic service brake 3 - Check level plug 4 - Breather 12 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual OIL DRAINING MANDATORY PROCEDURE OIL DRAINING MANDATORY PROCEDURE WARNING • • Do not attempt any maintenance if the axle is hot (40-50°C / 104-122°F). Hot oil and components can cause personal injury. Avoid skin contact. Wear protective gloves and glasses. Make sure all fluids are contained during inspection, maintenance, tests, adjustment and repair of the product. Prepare a suitable container to collect the fluid before removing any component containing fluids. Dispose of all fluids following legal and local regulations. CENTRAL HOUSING Before draining oil it is mandatory to loosen the oil filling plug or the breather (if present), and wait until the internal pressure is completely released. Remove the oil draining plug and drain oil only when the pressure is completely released. PLANETARY GEAR REDUCTION Before draining oil it is mandatory to rotate the planetary gear reduction in order to move the oil plug in filling position, then loosen the oil plug and wait until the internal pressure is completely released. Remove the oil plug and drain oil only when the pressure is completely released. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 13 MAINTENANCE INTERVALS MAINTENANCE INTERVALS Oil level check OPERATION All COMPARTMENT 100 - 250 whs max. * 10 whs 1ST CHANGE / CHECK (whs) 100 - 250 whs max. * 10 whs 10 whs Monthly FREQUENCY (whs) For details see below LUBRICANTS If with limited slip differential, and/or wet brakes, use LS additivated oils. Clean carefully oil plug magnet. Clean carefully oil plug magnet REMARKS Central body hypoid bevel gears - SAE80W/90 (API GL5) Supply grease until clean grease is visible from outside. Grease performance level acc. to: According to DIN 51825 level KP2K-30 (NLGI2) or KP3K-20 (NLGI3); ASTM D4950 NLGI2 GC-LB Check for any damage or corrosion of treads or mating surfaces DOT brake fluids oils are NOT compatible w/std oils Not applicable Clean carefully oil plug magnet. * in accordance with Machine Service requirements Clean carefully oil plug magnet. Central body standard bevel gears - UTTO (API GL4), or gear: J20/C, MF M1143, or gear: SAE80W/90 (API GL4 or GL5) 1000 whs UTTO (API GL4) J20/C; or gear: SAE80W/90 (API GL4 or GL5) Gears with wet discs clutch ATF GM Dexron IIE, Dexron III Only gears - UTTO J20/C, or gear: SAE80W/90 (API GL4 or GL5) 100 - 250 whs max. * Dropbox (if any) Every 500 whs Wheel nuts 10 whs 100 whs Negative brake (SAHR) For hydraulic actuations (brakes, SAHR, 100% diff. lock, etc.) use ATF oil e.g. GM Dexron IIE, Dexron III King Pin Tapered Bearings Service brake Seals 10 whs NLGI2 EP or NLGI3 EP with Moly Addittive NLGI2 EP or NLGI3 EP No lubricant allowed King Pin Bushings 10 whs Normal work – Weekly or Severe duty – Daily Every 200 whs Hub Reduction Differential Oil Change Adjustment Tightening Greasing Trunnion Bushings In case of severe duty, half oil change intervals must be applied. In case of extreme enviroments, chatter noise, reduce oil change intervals accordingly. In case of extremely low ambient temperatures (<-20°C), use appropriate oils w/ low viscosity: UTTO J20/D (std Bevel Gears), SAE 75W/90 API GL5 LS (Hypoid Bevel Gears: models 192, 193, 194). API GL5: Acc. To MIL L-2105-B See PSB 00279 (latest update) for more info regarding lubricants and viscosity grades. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 14 LUBRICANT & SEALANT SPECIFICATIONS LUBRICANT & SEALANT SPECIFICATIONS 1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor. 2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar products marketed by different brand names with different trade marks. LOCTITE 242 Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator. LOCTITE 243 The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces. LOCTITE 270 Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80° C approximately. LOCTITE 275 Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum diametrical clearance of 0.25 mm. LOCTITE 510 Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal clearances between flanges up to 0.2 mm. LOCTITE 577 Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so heating may be necessary for larger diameters. LOCTITE 638 Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with clearance ranging between 0.1 and 0.25 mm. LOCTITE 648 Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with radial clearance below 0.1 mm. AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS) Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter of sealing rings for rotating shafts with outer metal reinforcement. SILICONE Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and physical elements. Polymerises with non-corrosive dampness. TECNO LUBE/101 (SILICONE-BASED GREASE) Highly adhesive synthetic grease, with silicone compounds added. Applied to adjustment screws with hole communicating with oil-type fluids. Used when frequent adjusting is required. MOLIKOTE (DOW CORNING) Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sticking and oxidation of parts that are not lubricated on a regular basis. (LITHIUM-BASED) GREASE Applied to bearings, sliding parts and used to lubricate seals or parts during assembly. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 15 LUBRICANT & SEALANT SPECIFICATIONS 16 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SAFETY PRECAUTIONS 1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts mentioned should rest on supporting benches. 2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm. 3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po- sitioned and that the machine is locked lengthways. 4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the igni- tion key from the machine. 5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure that all torque wrenches have been checked and calibrated. 6 - During maintenance operations, always wear protective glasses, safety footwear, protective gloves and all P.P.E. (Personal Protective Equipment) in function of the risks which the workers may be exposed to. 7 - Should you stain a surface with oil, remove marks straight away. 8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste and dispose of them according to the relative law provisions obtaining in the country where the axles are being overhauled. 9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol, xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment friendly solvents. 10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some of the diagrams. 11 - After repair work has been completed, accurately touch up any coated part that may have been damaged. 12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle. 13 - Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a situation which, if not avoided, may result in damage to components. NOTICE Indicates information which may make product service easier to perform. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 17 LUBRICANT & SEALANT SPECIFICATIONS 18 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual PLANETARY REDUCTION EXPLODED VIEW 19 24 26 23 22 25 20 21 5 18 13 17 12 16 11 4 9 15 5 14 27 6 21 3 10 7 2 1 ITEM 27 NOT PRESENT ON ALL MODELS ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 19 DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. 3 FIGURE 3: Using two screwdrivers or two levers inserted in the slots provided, disjoin the planetary cover (3) away from the wheel hub (16). Remove the cover (3). 1 FIGURE 1: Carry out all operations one wheel side at a time. Remove the oil level plug (1) and drain the oil. 3 6 FIGURE 4: Remove the sun gear (6). 2 FIGURE 2: Attach a suitable sling to the satellite carrier cover, connect to lifting gear, and tighten. The approximate weight of the cover is 67kg (148lb). Remove the locking screws (2) of planetary cover (3). 4 5 FIGURE 5: Remove the snap rings (4) of the planetary gears (5). WARNING Removal of the snap rings can cause personal injuries. You must wear appropriate safety equipment. To avoid injury to eyes, wear eye protection equipment. 20 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual DISASSEMBLY 9 5 FIGURE 6: Remove the planetary gears (5). FIGURE 9: Remove the safety flange (9). 16 27 11 FIGURE 7: NOT PRESENT ON ALL MODELS Remove the spacer (27). FIGURE 10: Using two screwdrivers or two levers inserted in the slots provided, disengage the crown wheel (11) from the hub (16). Remove the crown (11). NOTE: Write down the direction of assembly of the spacer. 7 16 FIGURE 8: Loosen and remove the nuts (7) from the crown flange (11). ASM-0006E - 114 Axle Service Manual FIGURE 11: Tighten fully into the hole provided a double joint lifting eye size M12, connect to a suitable lifting gear and tension. The approximate weight of the hub is 42kg (92,5lb). With the help of a hammer, shift the hub (16) and the external bearing (14). Dana Holding Corporation 21 DISASSEMBLY 17 14 14 16 FIGURE 12: Extract the external bearing (14). FIGURE 15: Remove the external thrust blocks of bearings (14) and (17), using a pin driver. NOTE: Hammer in an alternate sequence to prevent clamping and deformation of the thrust blocks. 18 30-35 Bar P1 16 B1 FIGURE 13: Remove the seal ring (18) from the hub (16). B2 P2 NOTE: Write down direction of assembly. CAUTION The seal ring may not be reused. FIGURE 16: ONLY NEGATIVE BRAKE VERSION Connect an external pump to the union piece “P1“ of the negative brake and introduce a pressure of 30 - 35 bar to eliminate the pressure of the Belleville washers. WARNING 18 Hot oil and components can cause personal injury. Avoid skin contact. NOTE: Perform all operations on both arms. Remove the oil plug "A" and drain oil. FIGURE 14: Remove the internal bearing (18). 22 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual DISASSEMBLY 26 B FIGURE 17: If axle is positioned on an overhaul bench, place a safety anti-tilting stand “B” under the arm that remains connected and block wheels, if any. FIGURE 20: Remove the flange (26) complete with the discs. Noting down direction of assembly. For details, see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p. 39. 19 FIGURE 18: Connect a suitable sling to the arm, connect to lifting gear and tighten. The approximate weight of the arm complete with brakes and planetary gears is 351kg (774lb). A FIGURE 21: Remove the axle shaft (19). 1 4 21 20 3 FIGURE 19: Loosen and remove the screws (4) that attach the arm (3) to the central body (6). Remove arm together with brakes and axle shafts; lay down the arm vertically. FIGURE 22: Turn the arm over using the lifting gear. The arm was attached to the sling during dismantling. The approximate weight of the arm complete with brakes and planetary gears is 351kg (774lb). Using an extractor, remove seal ring (21) and guide ring (20). NOTE: Write down the direction of assembly of seal ring. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 23 ASSEMBLY ASSEMBLY Lubricate 20 T1 17 T3 14 FIGURE 23: Lubricate and fit the guide ring (20) onto tool T3 (See drawing T3 p. 31); install the rings into the arm. FIGURE 25: Position the wheel hub (16) under a press. Lubricate the seat of the bearing cones (14, 17) and, using tool T1 (See drawing T1 p. 29), install the bearing cup of the bearing cone (14, 17). CAUTION Pay particular attention to the direction of assembly of the rings. 17 21 T4 FIGURE 24: Lubricate and fit the seal ring (21) onto tool T4 (See drawing T4 p. 32); install the rings into the arm. FIGURE 26: Fit the bearing (17) and seal ring (18) into the internal thrust block. 18 CAUTION Pay particular attention to the direction of assembly of the rings. 16 FIGURE 27: Apply a joining compound for seals to the outer surface of the sealing ring (18). Position the sealing ring (18) in the hub (16). NOTE: Verify the ring (18) is correctly oriented. 24 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY 14 T2 FIGURE 28: Position tool T2 (See drawing T2 p. 30) and press the sealing ring (18) into its seat. FIGURE 30: Install the external bearing cone (14). NOTE: CAUTION Using a plastic hammer, drive the bearing cone to the limit stop by lightly hammering around the edge. Check the flatness of seal ring. 11 16 FIGURE 31: Fit the complete crown flange (11). FIGURE 29: Insert and tighten two doublejoint lifting eyes size M12. Connect to suitable lifting gear and tighten. The approximate weight of the hub is 42 kg (92.5 lb). Install the wheel hub (16). NOTE: In order to fasten the flange (11), use a plastic hammer and alternately hammer on several equidistant points. NOTE: Move the bearing cone to the limit stop by hammering lightly all around the edge. If assembly is difficult, use a driver with a suitable diameter to seat it. 9 FIGURE 32: Install the security flange (9). ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 25 ASSEMBLY 5 7 FIGURE 33: Tighten nuts (7) in two stages, using the crisscross method. Standard nuts: 214 -236 N·m + Loctite 243 Flanged nuts: 270 - 300 N·m + Driloc NOTE: Check the continuous rolling torque on the hub. Torque 15 - 64 Nm. 3 FIGURE 36: Insert the planetary gears (5) into the cover (3). Lock gears (5) into position by installing the snap rings. WARNING Personal injury can result when installing snap ring. The appropriate safety equipment must be worn. To avoid injury to your eyes, wear protective glasses during this procedure. 6 O-ring 15 FIGURE 34: Install a new o-ring (15) on the centering diameter of wheel hub. Lubricate the o-ring before fitting. FIGURE 37: Install the solar gear (6). 3 16 27 FIGURE 35: NOT PRESENT ON ALL MODELS Grease the spacer (27) assemble on the satellite gear (5) as shown in the figure. Accurately check the orientation. FIGURE 38: Fit the planetary carrier cover (3) onto the hub (16). CAUTION Check that the o-ring is in good condition and in position. 26 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY 40 - 50 N·m 3 2 grease FIGURE 39: Lock the planetary carrier cover (3) by tightening the screws (2). Torque wrench setting for screws: 40 - 50 N·m. 19 A FIGURE 42: Insert the end plate. Before installing the last brake disc and the end plate, spread grease over the contact surfaces to hold them in position while mounting on the central housing. 27 “A” FIGURE 40: Grease sealing face “A” of axle-shaft (19). Install the axle shaft (19) making sure it is properly engaged in the sun gear (6). FIGURE 43: Install the end plate (27) with the oil passage notch “A” facing downwards. NOTE: Be very careful not to damage the seal ring (21). O-ring Differential side B 26 FIGURE 41: 1 - Insert the brake discs (24, 25) in the right sequence, orient them so that the oil circulation holes and the marks "B" are perfectly lined up. 2 - Install the flange (26) on the arm. FIGURE 44: Check the condition and position of the cover's o-ring. NOTE: The first brake disc (3) to be inserted must be of steel material. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 27 ASSEMBLY Loctite 243 550 - 600 N·m FIGURE 45: The arm was attached to a sling during dismantling. The approximate weight of the arm complete with brakes and planetary reduction gear is 351kg (774lb). Install the complete arm. Apply Loctite 243 to the threads of the screws (3) and tighten to a torque of 550 - 600 N·m. 35 - 50 N·m FIGURE 46: Install the oil-level plug (1). Torque wrench setting for screws: 30 - 50 N·m 28 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P/N: 910.04.4591 ø55 5x45° ø194 ø50H7 32 33 21 ø40 ø194 ø188 ø185 ø160 ø65 ø50H7 ø50n6 R 52 ø35 -0.1 -0.15 15 ø90H8 ø150 37 120 21 R5 50 M10 1 R2 R5 ø15 R5 20 15 35 20 17° 46,5 60 ° 60 ° 60 5x15° ø185 ø188 140 182 2 17° ø50 30 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 29 SPECIAL TOOLS T2 P/N: 910.06.4592 ø208 ø70 -0.08 -0.12 ø40 ø18 29 50 90° 10 ø20 230 ø8,5 4,5 1 25 10 4 1 20 M8 M10 ø30 45 25 ø70H7 ø145H7 ø158,2 ø164,5h8 ø194 47 42 10 ø30 11,5 ø24H11 ø18H11 -0.2 +0. +0.3 -0. 27 17 21 ø8 51,5 20 29 ø8 16 26 24 -0.3 +0. 50 ø25 160 140 ø145g6 ø70g6 ø32 45 50 ø11 87 67 -0.3 +0. 56 25 ø18 ø24 30 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS T3 P/N: 910.06.4594 ø55p6 ø70 ø40 3x15° 3x15° 223 ø70 3x15° ø55H7 13 28 ø42 126 15° 105 151 85 10 89 20 ø56 -0.1 -0.2. ø51 ø57 ø67 ø71 ASM-0006E - 114 Axle Service Manual -0.3 -0.4 Dana Holding Corporation 31 SPECIAL TOOLS T4 P/N: 910.04.4595 ø84 ø55p6 ø70 ø40 85 3x45° 89 20 10 3x15° ø56 ø40 ø55H7 -0.2 +0. 5x15° 3 110 94 112 89 -0.2 +0. 151 0.8 15° ø49,5 ø70 ø69,5 -0.3 ø71 -0.4 32 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SERVICE BRAKE EXPLODED VIEW 1 14 3 4 7 8 9 10 11 2 5 6 12 13 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 33 DISASSEMBLY DISASSEMBLY DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle. CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. NOTE: Perform all operations on both arms. Remove the oil plug "A" and drain oil. FIGURE 3: Remove arm together with brakes and axle shafts; set the arm in a vertical position using suitable brackets to keep it locked in place. Release pressure. B 1 A FIGURE 1: If axle is positioned on an overhaul bench, place a safety anti-tilting stand “B” under the arm that remains connected and block wheels, if any. FIGURE 4: Write down the order of assembly and remove the end plate (1). 2 FIGURE 2: Attach a suitable sling to the arm, connect to lifting gear and tighten. The approximate weight of the arm complete with brakes and planetary gears is 351 kg (774 lb). Remove the retainer screws. 34 Dana Holding Corporation FIGURE 5: Remove braking discs (2, 3), noting down direction of assembly. NOTE: If disks are not to be replaced, avoid changing their position. ASM-0006E - 114 Axle Service Manual DISASSEMBLY 4 5 FIGURE 6: Remove the flange (4) complete with the discs. Noting down direction of assembly. FIGURE 9: Remove the adjusting screws (5). 14 9 FIGURE 10: Slowly introduce low-pressure compressed air through the connection member for the service brake, in order to extract the piston (9). FIGURE 7: Remove the axle shaft. NOTE: Be very careful not to damage the seal ring. CAUTION Hold the piston (9) back, as it may be suddenly ejected and damaged. 7 8 FIGURE 8: Remove the reversal springs (8) and screws (7). NOTE: If the springs (8) are weak or deformed they must be replaced. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 35 ASSEMBLY ASSEMBLY 9 9 FIGURE 13: Using a plastic hammer, install the piston (9) into the arm. FIGURE 11: Insert the stroke automatic regulation springs (6); place them in line with the piston (9). NOTE: Lightly hammer all around the edge in an alternate sequence. 5 - 7 N·m Driloc 5 FIGURE 12: Fit o-ring (11, 12) and back-up ring (10, 13) onto the piston (11). Lubricate the piston and the o-rings and install the unit into the arm. O-ring FIGURE 14: Fit the adjusting screws (5). Torque wrench setting: 5 -7 N·m. CAUTION Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. Back up ring 36 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY first disc 7 15 - 20 N·m Driloc 3 8 FIGURE 15: Fit the reversal springs (8) on the piston (9). Tighten with torque wrench setting of 15 - 20 N·m FIGURE 17: Insert the brake discs in the right sequence. NOTE: The first brake disc (3) to be inserted must be of steel material. CAUTION Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. second disc 2 A FIGURE 18: The second brake disc (2) to be inserted must be of friction material. FIGURE 16: Grease sealing face “A” of axle shaft . NOTE: Differential side Be very careful not to damage the snap ring . 13 FIGURE 19: Install the flange (4) on the arm. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 37 ASSEMBLY grease FIGURE 20: Insert the end plate (1). Before installing the last brake disc and the end plate (1), spread grease over the contact surfaces to hold them in position while mounting on the central housing. 1 FIGURE 23: The arm was attached to a sling during dismantling. The approximate weight of the arm complete with brakes and planetary reduction gear is 351 kg (774 lb). Check condition and position of the arm's o-ring; install the complete arm. NOTE: To assist axle shaft centering, slightly move the wheel hub. Loctite 243 “A” FIGURE 21: Install the end plate (1) with the oil passage notch “A” facing downwards. O-ring FIGURE 24: Temporarily lock the arm with nuts previously coated with Loctite 243; tighten lightly to make the unit touch the main body. 550 - 600 N·m FIGURE 22: Install the new o-ring. Lubricate before installing. FIGURE 25: Secure in position with the screws (3) tightening to a torque of 550 - 600 N·m. 38 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SERVICE BRAKE AND NEGATIVE PARKING BRAKE EXPLODED VIEW 6 3 4 7 8 1 4 2 29 29 28 18 30 16 9 10 27 17 26 25 30 15 14 11 12 19 13 20 21 22 23 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 39 RELEASE RELEASE ADJUSTMENT Tecno Lube 101 23 21 22 23 FIGURE 1: Loosen nuts (22) of screws (23) provided for the mechanical and manual release of the braking units, then move the nuts backwards by approximately 8 mm. FIGURE 4: Remove screws complete with nuts and seals. Replace seals, apply silicone-based Tecno Lube /101 grease to the screws and install all parts into the arm. 34 mm 23 FIGURE 2: Tighten screws (23) to fasten the pressure plate (16). FIGURE 3: Using a wrench, tighten the screws (23) in an alternate sequence by 1/4 turn at a time so as to compress the Belleville washers (1) and disengage the braking disks. FIGURE 5: Adjust screws (23) to obtain a distance of 34 mm in relation to the arm. FIGURE 6: Lock into position with nuts (22). CAUTION CAUTION Tighten maximum by one turn. 40 Dana Holding Corporation Hold screws (23) into position while locking the nuts (22); after locking, check the distance of screws (23) once more. ASM-0006E - 114 Axle Service Manual DISASSEMBLY DISASSEMBLY 30-35 Bar DANGER P1 Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle. P1 B2 B1 P2 CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. FIGURE 9: Connect an external pump to the union piece “P1“ of the negative brake and introduce a pressure of 30 - 35 bar to eliminate the pressure of the Belleville washers (1). M16 DANGER Always check that the hydraulic circuit test for leaks under pressure. Always use a cardboard or a panel to control the loss. A leak from a hole of the size of a pin can cause serious injury. If fluid is injected into the skin it is necessary to seek immediate medical care. NOTE: FIGURE 7: Insert and tighten two double joint lifting eyes size M16. Connect to suitable lifting gear and tighten. The approximate weight of the unit is 150 kg (331 lb). Remove fastening screws from the reduction unit. Perform all operations on both arms. Remove the oil plug "A" and drain oil. B A FIGURE 8: Disjoin the entire reduction unit from the axle and place it on a bench. ASM-0006E - 114 Axle Service Manual FIGURE 10: If axle is positioned on an overhaul bench, place a safety anti-tilting stand “B” under the arm that remains connected and block wheels, if any. Dana Holding Corporation 41 DISASSEMBLY 0 bar FIGURE 11: Attach a suitable sling to the arm, connect to lifting gear and tighten. The approximate weight of the arm complete with brakes and planetary gears is 351 kg (774 lb). FIGURE 14: Gradually release the pressure in the braking circuit, bringing it to zero through the external pump. DANGER Do not remove any part of the hydraulic circuit without having completely released the hydraulic pressure. The removal of pressurized parts or loss caused from releasing these components can cause serious injuries and even death. A leak from a hole of the size of a pin can cause serious injury. If fluid is injected into the skin it is necessary to seek immediate medical care. FIGURE 12: Remove the retainer screws. FIGURE 15: Gradually loosen the sleeve and remove. DANGER FIGURE 13: Remove arm together with brakes and axle shafts. Set the arm in a vertical position using suitable brackets to keep it locked in a safe condition. 42 Dana Holding Corporation Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve connected to the brake. ASM-0006E - 114 Axle Service Manual DISASSEMBLY 11 16 14 FIGURE 16: Remove braking discs (11, 12), noting direction of assembly. FIGURE 19: Remove the adjusting screws (14) from the counterwasher (16). NOTE: If disks are not to be replaced, avoid changing their position. 10 9 13 FIGURE 20: Remove the reversal springs (9) and screws (10). NOTE: FIGURE 17: Remove the flange (13) complete with the discs, noting direction of assembly. If the springs (9) are weak or deformed they must be replaced. 19 20 16 FIGURE 18: Remove spacer braking discs (19) and shims (20), noting direction of assembly. ASM-0006E - 114 Axle Service Manual FIGURE 21: Write down the order of assembly and remove the counterwasher (16). Dana Holding Corporation 43 DISASSEMBLY M20 25 FIGURE 22: Tighten two safety M20 studs in the main body. Loosen the capscrews (29) using the criss-cross method and remove them. FIGURE 25: Slowly introduce low-pressure compressed air through the connection member for the service brake (P2), in order to extract the piston (25). CAUTION Hold the piston (25) back, as it may be suddenly ejected and damaged. 1 17 FIGURE 23: Move the cover (17) outwards while supporting the Belleville washers (1). Remove the Belleville washers (1) and write down direction of assembly. 3 FIGURE 26: Slowly introduce low-pressure compressed air through the connection member for the negative brake (P1), in order to extract the piston (3). CAUTION 17 Hold the piston (3) back, as it may be suddenly ejected and damaged. Write down the order of assembly. FIGURE 24: Attach a suitable sling to the brake cover, connect to lifting gear, and tighten. The approximate weight of the brake cover is 45kg (99lb). Remove the studs. Remove the brake cover (17). 44 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY ASSEMBLY O-ring 3 4 18 Back up ring 17 O-ring 2 FIGURE 29: Using a plastic hammer, install the piston (3) into the cylinder (17). NOTE: Lightly hammer all around the edge in an alternate sequence. 27 FIGURE 27: Fit o-ring (2) and (4) and anti-extrusion ring (18) onto the piston (3). 25 FIGURE 30: Fit o-ring (27) and anti-extrusion ring (26) onto the piston (25). 17 26 O-ring Back up ring FIGURE 28: Check the position of the anti-extrusion (18) and o-rings (2) and (4). Lubricate the piston and the o-rings and install the unit (3) into the cylinder (17) . FIGURE 31: The o-rings always have to be assembled from the pressure facing side. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 45 ASSEMBLY 25 17 FIGURE 32: Lubricate the piston and the o-rings and install the unit (25) into the cover (17) . FIGURE 35: Install the new o-ring. Grease before installing. 25 17 Grease 1 FIGURE 33: Using a plastic hammer, install the piston (25) into the cover (17). FIGURE 36: Position the Belleville washers (1) and engage the cylinder. Spread grease over the contact surfaces to hold them in position. NOTE: Lightly hammer all around the edge in an alternate sequence NOTE: Check the direction of Belleville washers (1) and relative centering. 5 M20 17 FIGURE 34: Assemble the bleed valve (5) and the new o-ring. Grease before installing. 46 Dana Holding Corporation FIGURE 37: Connect a suitable sling to the satellite carrier cover, connect to lifting gear and tighten. The approximate weight of the cover is 67kg (148lb). Tighten two safety M20 studs in the main body. Engage the cover (17). ASM-0006E - 114 Axle Service Manual ASSEMBLY 129 - 143 N·m Loctite 243 P1 17 B2 B1 P2 30 - 35 Bar FIGURE 38: Insert the screws (29) and tighten them alternately. Tightening the screws (29) to a torque of 129 - 143 N·m. Remove the studs. FIGURE 41: Connect an external pump to the negative brake (P1) and introduce pressure to 30 -35 bar. DANGER 15 Always check that the hydraulic circuit test for leaks under pressure. Always use a cardboard or a panel to control the loss. A leak from a hole of the size of a pin can cause serious injury. If fluid is injected into the skin it is necessary to seek immediate medical care. 19 9 10 FIGURE 39: Insert the stroke automatic regulation springs (15); place them in line with the intermediate disc (19). 15 - 20 N·m Driloc FIGURE 42: Fit the reversal springs (9) and screws (10) on the intermediate disk (16). Tighten with torque wrench setting of 15 -20 N·m CAUTION FIGURE 40: Insert the intermediate disc (19). ASM-0006E - 114 Axle Service Manual Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. Dana Holding Corporation 47 ASSEMBLY 5 - 7 N·m Driloc 14 FIGURE 43: Install the adjusting screws (14) on the threads and tighten to 5-7 N·m. Arm fix x measurement = 90.5 ± 0.05 mm quote = 90,5 FIGURE 46: Arm fix measurement = 90.5 - 0.05 mm Y = brake gap CAUTION Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. S 20 X S = 90,5 mm - (x + y + v) FIGURE 47: Y = 1.5 mm = brake gap S = 90.5 mm - ( x + y + v ) = Thickness of shims to insert under the shim washer. Tolerance = - 0.1 mm EXAMPLE: 90.5 mm - (30.2 + 57.5 + 1.50) = S = 1.30 mm FIGURE 44: Take the measurement “X” from the surface of the intermediate disk to the cover sealing surface with 30 - 35 bar of pressure introduced. EXAMPLE: X = 30.2 mm V 1000Kg S 20 20 FIGURE 48: Grease the shims S (20) and assemble in position on the spacer braking disc (19), then insert them in the arm. NOTE: Make sure the shims are inserted correctly. FIGURE 45: Put the brake disc pack including the shim under a press, load with 1000 kg and take the measure “V”. EXAMPLE: V = 57.5 mm 48 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY 11 19 12 “A” FIGURE 49: Install the spacer braking disc (19) with the oil passage notch “A” facing downwards. FIGURE 52: Insert the brake discs (11) and (12) in the right sequence. Spread grease over the contact surfaces to hold them in position while mounting on the central housing. NOTE: B 11 The last brake disc to be inserted must be of steel material. FIGURE 50: Slightly lubricate the braking disks (11, 12) and fit them in the arm following the correct sequence. Orient them so the oil circulation holes and the marks “B” are perfectly lined up. Differential side FIGURE 53: The arm was attached to a sling during dismantling. The approximate weight of the arm complete with brakes and planetary reduction gear is 351 kg (774 lb). Check condition and position of the arm's o-ring; Install the complete arm. NOTE: To assist axle shaft centering, slightly move the wheel hub. 13 FIGURE 51: Install the flange (13) on the arm. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 49 ASSEMBLY Loctite 243 0 bar FIGURE 54: Temporarily lock the arm with nuts previously coated with Loctite 243; tighten lightly to make the unit touch the main body. 550 - 600 N·m FIGURE 56: Gradually release the pressure in the braking circuit, bringing it to zero through the external pump. DANGER Do not remove any part of the hydraulic circuit without having completely released the hydraulic pressure. The removal of pressurized parts or loss caused from releasing these components can cause serious injuries and even death. A leak from a hole of the size of a pin can cause serious injury. If fluid is injected into the skin it is necessary to seek immediate medical care. FIGURE 55: Secure in position with the screws (3) tightening to a torque of 550 - 600 N·m. FIGURE 57: Gradually loosen the sleeve and remove. DANGER Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve connected to the brake. 50 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual DIFFERENTIAL EXPLODED VIEW 29 16 17 23 26 18 26 24 23 20 29 26 6 1 23 26 15 3 13 28 14 4 4 20 27 12 5 26 7 10 5 8 11 4 5 3 1 7 5 ASM-0006E - 114 Axle Service Manual 4 Dana Holding Corporation 51 DISASSEMBLY DISASSEMBLY CAUTION T1 Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. FIGURE 3: Only if needing removing or adjusting, uniformly heat the ring nuts (1) up to a temperature of 80° C. Using tool T1, loosen and remove the ring nuts (3). NOTE: Accurately remove any trace of sealant from the threads of ring nuts and intermediate covers. FIGURE 1: Attach a suitable sling to the arm, connect to lifting gear and tension. The approximate weight of the arm complete with brakes and planetary gears is 351 kg (774 lb). Sling the arm to be removed and connect it to a hoist. Remove the retainer screws and relative washers. For details, see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p. 39. 1 6 FIGURE 4: Tighten two safety M20 studs in the main body. Loosen and remove the check screws (6) of intermediate cover (7) on ring gear side. FIGURE 2: Only if needing removing or adjusting, mark the position of the ring nuts (1). Remove the capscrews (3) from the ring nuts (1). 7 FIGURE 5: Disjoin the cover (7) ring gear side. 52 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual DISASSEMBLY 13 14 FIGURE 6: Remove the cover and studs. FIGURE 9: Remove the snap ring (13) and the cap (14). WARNING 28 Removal of the snap rings can cause personal injuries. You must wear appropriate safety equipment. To avoid injury to eyes, wear eye protection equipment. 4 FIGURE 7: Insert an adequately keyed bar in the differential. Connect the bar to suitable lifting gear. The approximate weight of the differential complete with crown wheel is 60 kg (132 lb). With the help of a bar extract the complete differential unit (28). 9 O-ring 7 FIGURE 10: If the bearings need replacing, extract the external thrust blocks of the bearings (4) from middle cover (7). NOTE: Inspect the o-ring (9). 6 4 FIGURE 8: Tighten two safety M20 studs in the main body. Loosen and remove the intermediate cover (4) screws (6). 4 28 FIGURE 11: If the bearing needs replacing, extract the bearings (4) from the differential carrier (28). ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 53 DISASSEMBLY 25 16 18 FIGURE 12: Remove the ring gear (18) capscrews (16). FIGURE 15: Remove the planetary gear (25). 27 23 26 FIGURE 13: Remove the screws (27) joining the differential unit half box. FIGURE 16: Remove shafts (24), complete with planetary gears (26) and spherical shoulder washers (23). NOTE: Mark the coupling marks. 29 25 19 26 25 FIGURE 17: Extract from the differential unit (17) the 2nd planetary gear (25). Remove the 2nd clutch pack (29) and shim set (19). FIGURE 14: Remove the upper half box (26) and remove the clutch pack (29). CAUTION CAUTION If the clutch pack does not need replacing, avoid swapping discs position. If the clutch pack does not need replacing, avoid swapping discs position. 54 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY ASSEMBLY 27 29 25 Driloc FIGURE 21: Assemble the half box with screws (27). FIGURE 18: Insert the planetary gear (25) and the whole friction unit (29). 23 CAUTION The match marks on the two half-boxes must correspond. Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. 71.5 - 78.5 N·m 26 FIGURE 19: Install the planetary gears (26) and spherical shoulder washers (25) onto the bolts (24). Install the planetary gear set. 19 FIGURE 22: Fit the complete differential unit in a vice and tighten the screws (27) holding the two half boxes together to a torque of 71.5 - 78.5 N·m. CAUTION 25 25 Tighten screws using the criss-cross method. FIGURE 20: Insert the planetary gear (25) and the whole friction unit (29). ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 55 ASSEMBLY 16 18 Driloc FIGURE 23: Mount the ring gear (18) and fasten it to the differential with screws (16). FIGURE 25: Position the differential unit under a press and, using a driver with an adequate diameter, install the first bearing (4). Turn the unit upside down and install the second bearing (4). CAUTION Use only new screws pre-treated with Driloc locking adhesive. Threads must be cleaned from oil. Degrease only non pre-treated threads. CAUTION Pay particular attention; position a shim with adequate diameter in order to engage the internal ring of bearing without engaging the cage. 139 - 154 N·m 4 7 FIGURE 24: Lock the ring gear (6) by tightening the screws (4) to a torque of 139 - 154 N·m. FIGURE 26: Only if bearings are replaced, insert the thrust blocks of the bearings (4) into the intermediate covers (7). CAUTION Use the criss-cross method. O-ring 9 FIGURE 27: Install the new o-ring. Lubricate before installing. 56 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY 129 - 143 N·m 129 - 143 N·m 6 6 7 FIGURE 28: Install the intermediate cover (7) the opposite side of the ring gears; lock cover with screws (6). Tighten screws to a torque of 129 - 143 N·m. FIGURE 31: Tighten screws (6) to a torque of 129 - 143 N·m. CAUTION CAUTION Use only new screws pre-treated with locking adhesive. Use only new screws pre-treated with locking adhesive. T1 FIGURE 32: Only if ring nuts have been removed, tighten the ring nut (3) on ring gear side until clearances between pinion and ring gear are zeroed. Then, loosen by about 1/4 turn. 28 FIGURE 29: Position the differential unit (28) in the central body with the help of a bar and install the middle cover. 11 T1 7 C FIGURE 30: Tighten the two safety screws “C” into the main body (11) and install the intermediate cover (7). FIGURE 33: Only if ring nuts have been removed, preload bearings with ring nut (3) on non-ring gear side in order to increase the torque of the pinion. CAUTION In the case of used bearings, check thrust torque; in the case of new bearings, check continuous torque. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 57 ASSEMBLY Gap = 0.30 - 0.40 mm A FIGURE 34: FLANGED REDUCER VERSION ONLY Using an extractor for ball bearings, remove the external reduction unit bearing from the central box. FIGURE 36: Introduce a dial indicator “A” with long tracer through the hole provided for the cap. Position the tracer on the side of a tooth of the ring gear, approximately 5 mm from the outer rim; preload by about 1 mm and zero the comparator. As you hold the pinion in position, move the ring gear manually in both directions to check clearance between pinion and ring gear. Standard clearance: 0.30 - 0.40 mm T2 T1 FIGURE 35: Apply onto the pinion (10) the bar-hold T2 (See drawing T2 p. 62) and with the help of a torque meter and check that torque will increase by 0.5 - 1.0 N·m as a result of differential bearing preload. Example: pinion torque: 2.3 - 3.2 N·m Pinion + differential torque: 2.8 - 4.2 N·m. T1 FIGURE 37: Adjusting clearance between pinion and ring gear. To INCREASE: loosen the ring nut on ring gear side and tighten the ring nut on non-ring gear side by the same measure. To DECREASE: perform the same operations inversely. To rotate ring nuts, use special wrench T1 (See drawing T1 p. 61). 58 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY 13 FIGURE 38: Using a plug of suitable diameter, fit the external reduction unit bearing to the central box. 14 FIGURE 40: Using pliers, install the cap (14) with the snap ring (13). 23,8 - 26,2 N·m WARNING Personal injury can result when installing snap ring. The appropriate safety equipment must be worn. To avoid injury to your eyes, wear protective glasses during this procedure. 1 FIGURE 39: Install the screw into the hole and tighten to a torque wrench setting of 23.8-26.2 N·m. CAUTION Use only new screws pre-treated with locking adhesive. FIGURE 41: The arm was attached to a sling during dismantling. The approximate weight of the arm complete with brakes and planetary reduction gear is 351 kg (774 lb). Check integrity and position of the arm's o-ring; Install the complete arm. NOTE: To assist axle shaft centering, slightly move the wheel hub. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 59 ASSEMBLY Loctite 243 FIGURE 42: Temporarily lock the arm with screws previously coated with Loctite 243; tighten lightly to make the unit touch the main body. 550 - 600 N·m FIGURE 43: Secure in position with the screws (3) tightening to a torque of 550 - 600 N·m. 60 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P/N: 910.38.4830 VITE M14x40 DIN912 016.04.0429 SCATOLA CENTRALE 114.01.001.01 COPERCHIO INTERMEDIO 114.01.018.01 ATTREZZO 660.38.4830 CUSCINETTO INA LS 2035 ATTREZZO 660.38.4830 GHIERA 194.04.001.01 CUSCINETTO 005.09.0762 32016 DIN720 GABBIA A RULLINI 005.13.0169 CHIAVE A BUSSOLA MOMENTO T2-24 12 54 54 0,5 36,5 3x15° 8 17 31,5 +0.2 -0. Ø40 Ø30H7 Ø15 4,5 7 Ø20 Ø35,5 Ø14,5 +0.2 -0. 4,5 9 Ø45,5e9 Ø34,5J7 Ø28 Ø35,5 Ø34,5J7 30° Ø45 Ø14 Ø8 Ø34,5 8 9 N°2 PEZZI Ø10H11 35 7 SALDARE CON ELETTRODI UTP65 20 +0.1 -0.1 50 30 20 Ø10H11 5 5 55 10 68,5 Ø10H11 Ø165 50 +0.2 -0. R5 27 50 +0.1 -0.1 143 +0.1 -0.1 2 +0.1 -0.1 R5 Ø15H7 Ø24,5 Ø30H7 4,5 Ø20h7 4,5 Ø14g7 M8 Ø19,5 Ø34,5 Ø30g6 R3 57 185,5 STAMPIGL.N°DISEGNO 10 +0.1 -0.1 MAT.ACCIAIO Fe42 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 61 SPECIAL TOOLS T2 P/N: 910.04.4588 60 23 18 30 3x15° ø13,7H8 3x15° ø69 ø60H7-u7 ø47,8D9 ø30 ø48 ø60H7-u7 5x30° M6 16 15 13 55 62 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual BEVEL PINION EXPLODED VIEW 10 8 11 6 4 9 2 7 5 3 1 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 63 DISASSEMBLY DISASSEMBLY CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE p. 13. M16 FIGURE 3: Remove the complete arms and the differential unit. For details, see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p. 39 and SERVICE BRAKE p. 33. FIGURE 1: Install a double joint lifting eye size M16, connect to a suitable lifting gear, and tighten. The approximate weight of the unit is 150 kg (331 lb). Remove fastening nuts from the reduction unit. FIGURE 4: Tighten two safety M20 studs in the main body. Loosen and remove the capscrews (6) of intermediate cover (4). For details, see DIFFERENTIAL p. 51. 1 FIGURE 2: Disjoin the entire reduction unit (9) from the axle and place it on a bench. FIGURE 5: FLANGED REDUCER VERSION ONLY. Using an extractor for ball bearings, remove the external reduction unit bearing from the central box. 64 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual DISASSEMBLY 2 FIGURE 6: Remove the snap ring (2). 10 FIGURE 8: Extract the pinion (10) complete with the internal bearing cone (9), the spacer (6), and shims (8). NOTE: Take care not to bend the snap ring (2). NOTE: The bearing cups of the bearing cones remain in the central body. WARNING Removal of the snap rings can cause personal injuries. You must wear appropriate safety equipment. To avoid injury to eyes, wear eye protection equipment. T1A FIGURE 9: Remove the external pinion bearing (4). T1B FIGURE 7: Position wrench T1B (see drawing T1 p. 73) onto the ring nut (3) and apply bar hold T1A (see drawing T1 p. 73) to the pinion (10). Stop wrench T1B and rotate the pinion so as to release and remove the ring nut (3). 6 NOTE: If disassembly is difficult, heat the ring nut to approximately 212 °F [100 °C]. 7 FIGURE 10: Remove the spacer (6) and the calibrated spacer (7). ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 65 DISASSEMBLY 8 10 9 9 FIGURE 11: Using a puller and a press, remove the inner bearing cone (9) from the pinion (10). FIGURE 14: Insert a drift in the appropriate holes. Remove the bearing cup of the internal bearing cone (9) as well as the shim washers (8). 4 FIGURE 12: Remove the bearing cup of the bearing cone (4). 5 FIGURE 13: Remove sealing ring (5). 66 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual ASSEMBLY ASSEMBLY Shims “S” 6 mm calibrated block FIGURE 15: Reset a depth gauge on a calibrated block (whose known thickness is 6 mm.). D FIGURE 18: Calculate shims “S” for insertion under the bearing cup of the inner bearing cone using the following formula: S = 222.2 - (I + D) where: 222.2 = fixed dimension I = actual pinion center distance D = Total bearing thickness; EXAMPLE: S = 222.2 - (176.9 + 44.45) = 0.85 mm D = bearing tickness T5 5 FIGURE 16: With a calibrated block on a faceplate, allow the bearing cone to set by rotating them in both directions and by applying a vertical thrust position the calibrated block on the external bearing cups. Check overall thickness of bearing. D = 44,45 mm FIGURE 17: Check nominal dimension “INT” as marked on the pinion. Add up to or subtract from “INT” the variation indicated as “Y” to obtain the actual center distance “I”. EXAMPLE: I = (INT - Y) = 177 - 0,1 = 176,9 mm ASM-0006E - 114 Axle Service Manual FIGURE 19: Lubricate the outer surface of the new sealing ring (5) and fit it onto the main body (11) using tool T5 (See drawing T5 p. 78). FIGURE 20: Using special tool T2 (See drawing T2 p. 74). Partially insert the bearing cup of the bearing cones and shims. Dana Holding Corporation 67 ASSEMBLY 6 T3 10 T2 FIGURE 21: Connect the tension rod to the press and move the bearing cup of bearing cones into the seats. Disconnect the press and remove the tension rod. NOTE: Before starting the next stage, make sure the bearing cup has been completely inserted into its seat. FIGURE 24: Remove the depth gauge and remove tool and bearing cone kits from the main body. Reinstall every part, also introducing a spacer (6) the shims (7) between bearing cones (4, 9). Tighten the entire pack by hand until a rolling torque is definitely obtained. T3 H = A - B = 1,4 mm T3 FIGURE 22: CALCULATING PINION BEARINGS ROLLING TORQUE Introduce tool T3 (See drawing T3 p. 76) complete with bearings (10) into the central housing; tighten by hand to eliminate the axial gap. FIGURE 25: Introduce depth gauge “DDG” in tool T3 (See drawing T3 p. 76) and measure deviation “H” from the previous measurement. EXAMPLE: H = A - B = 1.4 mm. T3 S1 7 FIGURE 23: Introduce the tracer of a depth gauge ‘DDG' into either side hole of tool T3 (See drawing T3 p. 76). Reset the depth gauge with a preload of about 3 mm. 68 Dana Holding Corporation FIGURE 26: Deviation “H” must be added to a set value of 0.10 mm to obtain the calibrated spacer value “S1” (7) for insertion between inner bearing cone (9) and spacer (6). Dimension “S1” must be rounded off to the higher 5/100. EXAMPLE: S1=H+X=1.7 + 0.1 =1.7 mm ASM-0006E - 114 Axle Service Manual ASSEMBLY 10 9 9 FIGURE 27: Position the internal bearing (9) and the pinion (10) under a press; force the bearing onto the pinion. FIGURE 30: Heat the external bearing cone (9) to a temperature of about 212 F° [100 C°] and fit it on to the pinion (10). Loctite 270 7 S1 FIGURE 28: Insert spacer (6) and calibrated spacers “S1” (7). Refer and keep to the positions marked during disassembly. 6 3 FIGURE 31: Apply Loctite 270 to the thread of the pinion ring nut (3) and tighten the nut onto the pinion. T1A 10 T1B FIGURE 29: Oil seal ring lips. Fit the pinion (10), calibrated spacers “S1” (8) and spacer (6) in the main body (11). ASM-0006E - 114 Axle Service Manual FIGURE 32: Apply special wrench T1B (see drawing T1 p. 73) to the ring nut (3) and bar-hold T1A (see drawing T1 p. 73) to the pinion (10). Lock the wrench T1B and rotate the pinion using a torque wrench, up to a minimum required torque setting of 900 N·m. Dana Holding Corporation 69 ASSEMBLY T4 FIGURE 33: Apply onto the pinion (10) the bar-hold T4 (See drawing T4 p. 77) and with the help of a torque meter, check the torque of the pinion (10). Tightening Torque: 2.3 - 3.2 N·m 1 FIGURE 35: Using a plug of suitable diameter, fit the external reduction unit bearing (1) in the central box. WARNING CAUTION If torque exceeds the maximum value, then the size of shim “S1” (7) between the bearing cone (8) and the spacer (6) needs to be increased. If torque does not reach the set value, increase the torque setting of the ring nut (3) in different stages to obtain a maximum value of 1000 N·m. If torque does not reach the minimum value, then the size of shim “S1” (7) needs to be reduced. Personal injury can result when installing snap ring. The appropriate safety equipment must be worn. To avoid injury to your eyes, wear protective glasses during this procedure. 2 FIGURE 36: Re-install the differential unit and the intermediate cover. CAUTION FIGURE 34: Insert the snap ring (2). 70 Dana Holding Corporation If the crown has been replaced, reinstate clearances. For details, see DIFFERENTIAL p. 51. ASM-0006E - 114 Axle Service Manual ASSEMBLY 129 - 143 N·m Loctite 243 FIGURE 37: Re-install the arms. For details, see SERVICE BRAKE p. 33 and SERVICE BRAKE AND NEGATIVE PARKING BRAKE p. 39. FIGURE 40: Assemble the reduction unit onto the axle. Fasten the support planes (turn flange to assist assembly). Insert nuts by applying Loctite 243 and tighten to 129 - 143 N·m. O-ring FIGURE 38: Install the new o-ring. Lubricate before installing. FIGURE 39: The reduction unit was attached to a sling during dismantling. The approximate weight of the reduction unit is 150 kg (330 lb). Install the entire reduction unit. ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 71 SEAL RING REPLACEMENT SEAL RING REPLACEMENT DISASSEMBLY ASSEMBLY ONLY WHEN REPLACEMENT IS NECESSARY ONLY IF PREVIOUSLY DISASSEMBLED Remove the pinion seal ring following these instructions: If the pinion, the bearings or other components must be installed and adjusted, refer to the procedure BEVEL PINION p. 63 and DIFFERENTIAL p. 51. 1 - If disassembly is difficult, heat the check nut of the flange at 80°C. 1 - Fit the new seal ring in the main body. 2 - Oil seal ring lips and install flange. NOTE: Heating is meant to loosen the setting of Loctite on the nut. 3 - Apply Loctite 242 to the threaded part of the pinion. 4 - Insert o-ring the nut and tighten it using a torque wrench. Torque wrench setting: 280-310 N·m 2 - Loosen and remove the nut; also remove the o-ring. 3 - Remove the flange complete with guard. 4 - Remove the sealing ring. If the pinion, the bearings or other parts must be replaced, refer to the procedure BEVEL PINION p. 63 and DIFFERENTIAL p. 51. 72 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P/N: 910.38.4819 STAMPIGL.N° DISEGNO Ø99 151,5 42,8 129,5 24,8 7,3 20 37,9 52 R15 40 Ø5 Ø1 +0.02 -0.02 Ø110 Ø88 30° 6 Ø7 6,5 58 30 ° Ø63,5H7 Ø15 N°2 POSIZIONI A 180° 1,5 Ø95 Ø70H11 R4 90 +0.02 -0.02 8 12 15,5 160 30 MAT.ACCIAIO 41CrAlMo7 BONIFICATO R=90-110 NITRURATO HRC62-65 80 N°3 POSIZIONI N°2 POSIZIONI 52 MAT.ACCIAIO Fe42 6° +0.2 -0. FORI M12-N°3 POSIZIONI H7 29 +0.1 -0.1 15,5 +0.02 -0.02 30 Ø12 N°2 POSIZIONI 58 +0.02 -0.02 12 300 RICAVARE DA FLANGIA 114.04.014.01 SALDARE CON ELETTRODI UTP65 77 22 M8 MONTARE A CALDO T.200° STAMPIGL.660.38.4815-A MONTARE A CALDO T.200° ASM-0006E - 114 Axle Service Manual ZIGRINARE N°2 POSIZIONI A 90° 14,5 13 55 Ø30 22 Ø69h11 Ø60H7-u7 Ø47,8D9 Ø59 Ø48 Ø60H7-u7 Ø45 15 X MA Ø60 5x30° R2 M8 32 10 +0.1 +0.15 3x15° +0.1 +0.15 Ø50 25,4 3x15° 10 Ø37,7H8 18 42 25,4 12,7 29 MAT.ALLUMINIO ANTICORODAL SCANALATO INTERNO - INNER SPLINE N48x1,25x9H DIN5480 NUMERO DENTI - TEETH NUMBER Z=37 MODULO NORMALE - NORMAL MODULE m=1,25 ANGOLO DI PRESSIONE - PRESSION ANGLE 30° Dana Holding Corporation 73 SPECIAL TOOLS T2 P/N: 910.04.4583 32 38 23 ø117 ø115,5 ø57 ø42H8 ø124,5 ø109 27° ø100 ø62H8 ø102 ø20 17° 3x45° 5x15° 7,5 N°3 POSIZIONI A 120° 20 M8 26,5 56 68 ø75 81,5 31 40 M8 47,8 ø22H7 ø40 ø120d8 ø110 ø100 ø80H7 4x45° 30 10 10 M8 R3 7,5 8 +0.1 +0.3 17 15 65 74 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS P/N: 910.04.4583 259 51 10,5 6,5 A 12 Sez.A-A 30 ø62f7 ø57 ø61,5 ø42H7 ø60 ø80f7 90° 15° ø69H7 1 3x45° A 35 105 50 1 ø30g6 15° M24x1,5 15° M20x1,5 M20x1,5 ø35 ø21e9 R3 ø8 R 35 ø22g6 44 50 315 325 28 383 284 60 15 39 17 M42x3 M24x1,5 ø36 ø30H7 ø42e8 30 285 255 5 M6 250 N°4 POSIZIONI A 90° ø89 +0.2 +0.4 ø74,5 ø40 145 ø45 ø55 90 R5 10 30 FILETTARE M74x2 36 280 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 75 SPECIAL TOOLS T3 P/N: 910.04.4584 A +-0.01 190 +0.01 A +-0.01 77 -0.01 113 68 TRATTO ø50.8d8 60 ø8H11 A +-0.01 ø80 ø70H7-n6 ø60 ø20,2H7 ø38 A +-0.01 ø66 M AX ø50,8f7 ø37H7 ø50,8d8 R2 15 A +-0.01 20 56 40 +0.1 -0.1 70 178 115 65 100 3x15° 5 M6 ø8H8 20 15° M20x1,5 ø26 ø37j7 ø6 ø20,2j7 R1 40 A +-0.01 5 18 ø8H11 +0.1 -0.1 A 40 100 A +-0.01 A +-0.01 64 11 ø20,2H8 R3 ø75 ø20,2H8 ø54 ø70 R3 35 ø10 25 3x15° 45 36 A 76 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS T4 P/N: 910.04.4588 60 23 18 30 3x15° ø13,7H8 3x15° ø69 ø60H7-u7 ø47,8D9 ø30 ø48 ø60H7-u7 5x30° M6 16 15 13 55 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 77 SPECIAL TOOLS T5 P/N: 910.04.4591 310 40 150 3x15° ø22 ø25 ø18p6 ø120e7 11,3 VISTA DA A-A WIEW FROM A-A A ø18h7 13 -0.2 +0. 52 15 17 ° ø45 3x15° 34 89 70 45 3x15° ø77 3x15° 114 130 ø100 A 19,5 3x15° ø110 ø15 N°6 POSIZIONI ø68 ø69,5 ø89 ø99 ø111,1e7 78 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS T6 P/N: 910.04.4590 46 200 50 45° +0.1 -0.1 ø130 60 45° ø8 20 25 10 50 +0.1 +0.3 ø12H8 N°4 POSIZIONI N°4 POSITION ø90 ø12m6 ø150 N°4 PEZZIN°4 PIECES SPINA 12m6x50 DIN 6325 DOWEL 12m6x50 DIN 6325 12 36,5 31,5 8 N°2 PEZZI 9 3x15° ø34,5J7 ø28 ø35,5 35 ø14 54 ø34,5J7 ø10H11 9 ø34,5 ø8 ø20 ø14,5 ø40 ø30H7 17 30° ø15 8 ø35,5 ø45,5e9 54 ø45 CHIAVE A BUSSOLA MOMENTO T2-24 0,5 SALDARE CON ELETTRODI UTP65 4,5 +0.2 +0.2 -0. 4,5 -0. 7 +0.1 -0.1 50 30 20 5 ø10H11 ø24,5 ø14g7 4,5 2 27 +0.1 -0.1 50 +0.1 -0.1 M8 ø19,5 ø30g6 ø34,5 ø10H11 ø165 4,5 R5 50 143 +0.1 -0.1 ø30H7 R3 R5 ø15H7 5 ø20h7 20 7 +0.1 -0.1 +0.2 -0. 10 55 68,5 57 185,5 10 ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 79 SPECIAL TOOLS T7 P/N: 910.04.4586 100 22,5 -0.2 10 +0. 69,5 ø130 ø119 ø109 -0.2 -0.4 ø79,5 ø47,8H8 R5 ø15 ø60 12,5 3x15° 35 1 90 80 Dana Holding Corporation ASM-0006E - 114 Axle Service Manual SPECIAL TOOLS ASM-0006E - 114 Axle Service Manual Dana Holding Corporation 81 Copyright 2015 Dana Holding Corporation All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means, electronic or otherwise, without prior written approval. 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