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1. ASM 0004E 112 Axle Service Manual Dana Holding Corporation 81 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 D FIGURE 3 Remove the axial check springs 4 of shoes 3 NOTE To remove springs give a push and rotate so as to disen gage the catch in the rear seat A FIGURE 1 Move away the drum 1 and remove dust from the friction seals Use only an aspirator and a brush FIGURE 4 Remove the shoes 3 complete with the positio ning spring 5 Release the cable 6 for the parking brake function as well as the spring 5 4 k pei FIGURE 2 With a screwdriver disengage the return springs 2 of shoes 3 from the stopper 20 and extract them FIGURE 5 Remove the elastic compression bar set com pression bar 7 spring 18 washer 19 82 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY
2. 5 0004 112 Axle Service Manual SPECIAL TOOLS 2 P N 3424 24 5 0 0 1 2 3r 85 5 ZZ ls 5 co 5 z 8 0 8 gt T3 P N 2306 T3A T3B 028 5 02 019 95 T3C E amp 90 7 175 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 129 SPECIAL TOOLS T4 P N 3332 ZAJ OLO ZS 5 Y 1 0 1 038 5 7 255 A 263 065 190 Dana Holding Corporation ASM 0004E 112 Axle Service Manual LIMITED SLIP DIFFERENTIAL UNIT 25 AND 45 EXPLODED VIEW 45 VERSION VERSIONE 45 AUSFUHRUNG 45 VERSION 45 VERSION 45 15 d a A op W FB gt ar Oa x 19 10 VO lt S 14 TM 15 Se s Na 77 10 pU 18 VE ASM 0004E 112 Axle Service Manual Dana Holding Corporation 131 DISASSEMBLY DISASSEMBLY FIGURE 3 If bearing 5 needs replacing remove it remove crown 4 x NE RD FIGURE 1 Remove the whole differential unit 2 from the central axle unit 1 For details see DIFFERENTIAL UNIT p 55 FIGURE 4 Remove the planetary gear 6 and the whole fric tion unit 7 F
3. 71 EXPLODED VIEW TTD 71 DISASSEMBLY cm 72 ac tT 73 EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE 75 EXPLODED VIEW en 75 DISASSEMBLY xg seta taria 76 ASSEMBE iit 78 INCOMING DRUM BRAKE a 81 EXPEODEDSIEW veneree 81 DISASSEMBEr NEU ata 82 SE 5 Bh a esi 85 a vci 88 Frais a 88 BEVEL leni sque eens 89 FAPEODED VIE eccita 89 DISASSEMBLY A 90 se A 91 SPECIAL TOOLS _______ _ ee 92 bum pb 92 Je ea 93 4 INCOMING BRAKE 2 AND FUNCTION VERSIONS 95 EGPEOPDEDMEW CE ae pota 95 DISASSEMBL i u Lil 96 AOSE MBE Y T nA 100 im ze i mEEO SE ___ _________________ 106 EE A SEMEN 106 Reims 106 E RR RePEc UR TO 107 4 Dana Holding Corporation ASM 0004E 112 Axle Service Manual T GONBINED BRAKE i a 109 EAP EODE DYE S 109 mM HP UEM u ta a ACO ay 110 1 uisi ee E 113 RELEASE
4. oer sonm iB mm rsen mecs ar sonm e06 00m ax Sm e senm eor rinm jez senm rore fral sienm 1085 1156 1140 ss asm Moorem 2582577 Nm 2885 m ASM 0004E 112 Axle Service Manual Dana Holding Corporation 11 WHEEL NUT TIGHTENING TORQUES 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 ST 52 WHEEL NUTS WITH i 18 1 5 330 460 INTEGRATE 15 la M22 x 1 5 mm 630 N m 740 N m FLAT COLLAR WHEEL M18 x 1 5 mm 270 N m 360 N m NUTS WITH SEPARATE D SPHERICAL LOCK i M20 x 1 5 mm 360 N m 450 N m WASHER M22 x 1 5 mm 460 550 WHEEL NUTS WITH IN M18 x 1 5 mm 260 N m 360 N m TEGRATE SEAT CAPTIVE WASHER zu M20 x 1 5 mm 350 N m 500 s M22 x 1 5 mm 450 N m 650 N m MATERIAL ST 52 IS RECOMMENDED DANA AXLE APPLICATION IT IS THE OPTIMUM MATE RIAL FOR TIGHTENING THE RIM TO THE HUB NOTE The wheel nut tightening torque is related on
5. 25 DISASSEMBLX 26 SOPI aaa 30 SPECIAL TOOLS abili elia 34 inccr 34 RR 35 E IM I MM n EE 35 Re RR RR O M 36 ERRE IO RO ERO OSLO RA M cet 36 BEVEL PINION iii i 37 VIEW alli 3 DISA ENBEN cli 38 ASSE NIBE dire EEA A AE 41 SPECIAL TOO ES i i A E 48 KT iaia 48 p rr 49 Pelliccia JA 49 poc M W ES i A Sa 50 A 50 TO na anak o e I c t E 51 iii 52 JO coto OR A I E 52 iaia 53 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 3 DIFFERENTIAE UNIT poc 55 EXREOPEDMEW AO lee 55 DISASSEMB U A 56 58 Oblati 60 n ccr E E 60 Dor m ICD 60 MANUAL EMERGENCY RELEASE J 61 EXPLODED VIEW mu OP Dawa e 61 RELEASE TA 62 ADJUSTMENT sipario lie 63 MECHANICAL PARKING BRAKE 65 EP PLOBDEDVIEN Rella 65 DISASSEMBLY alma 66 leali A ME 68 EXTERNAL HYDRAULIC NEGATIVE BRAKE
6. 0130 0 0144 5 92 0167 0173 0195 N 2 POSIZIONI A 180 60 1 e 58 5 lt N 5 o a 5 OWEJ A 171 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T3 DETTAGLIO X SCALA 151 VEDI DETTAGLIO gt A SEZIONE A A FER UMS 28 0 2 46 ta 0 8 ED i 3 25 pge gt PROTEGGERE DALLA DETTAGLIO SCALA 1 1 172 Dana Holding Corporation ASM 0004E 112 Axle Service Manual lt e LL T4 Proteggere da 30 x cementazione 66666 PEC 2020230000 55555050505 22 RR OLIO RARI SK 9200 09 999990004 RARI 25 25 ZA 019 2920 29200 29200 245 3Xx45 5 525 55 eS 5 eS 5 94 555 SOO 25955 130 140 173 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 174 Dana Holding Corporation ASM 0004E 112 Axle Service Manual FLANGED PINION GEARBOX WITH FLOATING FLANGE EXPLODED VIEW ASM 0004E
7. AC A 117 gap E 118 merce UN 118 Dol 119 NORMAL DIFFERENTIAL UNIT ro i teo i ia pi 121 EXPLODED VIEW clelia 121 DIGAO EMBU Ea 122 Jalla 125 ke O a ee er ata 128 IEEE 128 qe MEI M MM UM E MM M nU M EE 129 E IMEEM IMMER EPI 129 Tus aa fi O SO E TONCO 130 LIMITED SLIP DIFFERENTIAL UNIT 25 AND 45 T 131 EXPLODED VIEW A mau NARA ECO RZA O A r WAD 131 exc ce ree Pe mn 132 ASSEMBE ae 135 SPE GIAL TOOLSE elite 138 EER 138 Eee A A II 139 4137 p 139 A 140 HYDRAULIC DIFFERENTIAL LOCK cae GE eese Coop eee veces 141 Ea LE 141 DISASSEMB IE ail 142 ROSEMBE i ar 145 SPEGIALTORES l ree er GAR 147 iba 147 Cilicia 147 HYDRAULIC NEGATIVE BRAKE sl LR nti 149 EXPEODED VIE VN MM C 149 DISASSEMBLY biliari a 150 O PIP Y aiar 154 PLANETARY REDUCTION69 u x d 161 FAPEODED T cc 161 i A a at 162 BL a tr
8. FIGURE 6 Fit tool T1A See drawing T1 88 and loosen the FIGURE 9 Remove the flange 12 complete with braking check nut 8 of the flange 9 cylinder clearance regulation unit and parking function ca ble FIGURE 8 Loosen the securing screws 11 of the brake unit flange 12 FIGURE 11 Remove the brake support 14 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 83 DISASSEMBLY FIGURE 12 Remove the sealing ring 15 from the brake sup port 14 NOTE Write down direction of assembly FIGURE 13 ONLY IF NECESSARY Remove snap ring 16 and screws 17 from the flange 9 84 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 17 Apply Loctite 242 to the screws 13 and tighten using the criss cross method Torque wrench setting 116 128 N m FIGURE 14 ONLY IF PREVIOUSLY REMOVED Insert the screws 17 into the flange 9 and hold them in po sition with the snap ring 16 FIGURE 18 Lubricate the coupling surfaces and fit the flange of the brake unit 12 FIGURE 15 Lubricate the sealing ring 15 and with the help of tool T2 fit it into the brake support 14 NOTE Carefully check direction of assembly FIGURE 19 Apply Loctite 242 to the screws 11 and tighten using the criss cross method TA ma 4 U ke EC e FIGURE 16 Lubricate the coupling surfaces and position the brake
9. t FIGURE 2 Mark the position of the ring nuts 1 Remove the capscrews 3 from the ring nuts 1 FIGURE 6 Insert a screwdriver in the opposing slots then for ce and remove the middle cover 5 and the complete diffe rential unit i FIGURE 3 Uniformly heat the ring ture of 80 C 29 NB Np 7 0 NOTE nuts 1 up to a tempera Support the pieces using a rod 56 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY t 3277 FIGURE 7 If the bearings need replacing extract the external thrust blocks of the bearings 7 and 8 from middle cover and central body NOTE Accurately check the o ring 6 FIGURE 8 Remove the top plug 7 NOTE The cap must be replaced each time the unit is disassem bled ASM 0004E 112 Axle Service Manual Dana Holding Corporation of ASSEMBLY ASSEMBLY ce between pinion and crown is zero then lock the crown go FIGURE 9 If the bearings are replaced insert the external back 1 4 1 2 turn thrust blocks in the middle cover 5 and in the central body 2 NOTE If the ring nuts 1 are removed coat them with Loctite 242 2 with the help of a bar and fit the middle cover 5 FIGURE 13 Pre set the bearings by means of the ring nut si tuated on the opposite side of the crown so as to increase Thoroughly check the state of the o ring 6 and make pinion torque up to 140 210
10. FIGURE 9 Remove the safety flange 7 FIGURE 12 Remove the crown flange 6 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 27 DISASSEMBLY FIGURE 13 Partially extract the hub 3 using a plastic ham FIGURE 16 Remove snap ring 10 from the arm 9 mer NOTE Tap on alternate sides to loosen hub FIGURE 18 Remove the internal bearing 15 FIGURE 15 Extract the hub 3 28 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY Lk Me FIGURE 19 Remove the external thrust blocks from the be arings 8 and 17 force a pin driver into the appropriate slots on the hub 8 NOTE Hammer in an alternate way so as to avoid clamping or deformation of the thrust blocks ASM 0004E 112 Axle Service Manual Dana Holding Corporation 29 ASSEMBLY ASSEMBLY FIGURE 23 Fit the bearing 15 into the internal thrust block ii m FIGURE 20 Position the lower part of tool T1A See drawing T1 p 34 and the thrust block of the external bearing 8 under the press FIGURE 24 Apply a sealant for removable seals to the outer surface of the sealing ring 16 Position the sealing ring 16 in the hub 9 FIGURE 21 Lubricate the seats of the bearings and position NOTE thrust block of the internal bearing 17 NOTE Check that the thrust block is correctly oriented K ce FIGURE 25 Position tool T2 See drawing T2 p 35 and press t
11. ta ae 1 OT i FIGURE 4 Remove the cover 7 complete with piston 15 reversal springs 10 11 and o ring 8 NOTE Check the o ring 8 and if necessary replace it FIGURE 2 Loosen and remove nut 2 o ring 3 and flange 4 If disassembly proves to be awkward heat the nut 2 at about 80 C If necessary use one of the T1 See drawing T1 p 118 tools FIGURE 5 Loosen and remove the check screws 12 of cylinder 13 110 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY A TA 7 M FIGURE 6 By prying with a lever remove the cylinder 13 complete with the piston 15 of the negative brake and the intermediate disc 16 FIGURE 9 Gently introduce compressed air through the ser vice brake connection point to extract the piston 26 zem d m y i 4 MN 8 k 4 FIGURE 7 Remove the coupling 21 and the braking discs 22 23 FIGURE 10 Remove the snap ring 9 from the cover 7 NOTE Write down the direction of assembly and replace the ring 9 each time the unit is disassembled e FIGURE 8 Loosen and remove the pin type screws 24 and the piston 26 reversal springs 25 FIGURE 11 Remove o rings 27 29 and anti extrusion rings 28 30 from the piston 26 of the service brake NOTE The snap rings 17 19 and anti extrusion rings 28 30 must be replaced each time
12. FIGURE 40 Slightly lubricate the braking disks 14 and fit them in the arm following the correct sequence orient them so that the oil circulation holes and the marks B are lined up When installing the steel discs the slot corresponding to the oil level cap should always be kept free FIGURE 41 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 158 Dana Holding Corporation FIGURE 42 Torque wrench setting A 200 N m B 283 N m NOTE Tighten using the criss cross method 4 n sz EB FIGURE 43 Gradually release the pressure in the braking cir cuit bringing it to zero through the external pump Do not remove any part of the hydraulic circuit without ha ving completely released the hydraulic pressure The removal of pressurized parts or loss caused from relea sing these components can cause serious injuries and even death A leak from a hole of the size of a pin can cause se rious injury If fluid is injected into the skin it is necessary to seek immediate medical care 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 44 Gradually loosen the sleeve and remove Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake ASM 0004E 112 Axle Service Manual Dana Holding Corporati
13. ASM 0004E 112 Axle Service Manual Dana Holding Corporation 139 SPECIAL TOOLS T4 P N 3332 g385 4 il oa O55 063 265 140 Dana Holding Corporation ASM 0004E 112 Axle Service Manual HYDRAULIC DIFFERENTIAL LOCK EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 141 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Remove the security switch 2 NOTE Check the state of the o ring 9 FIGURE 1 Remove the arms For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 NO 3 FIGURE 2 Remove the top cap 1 NOTE The cap must be replaced each time the unit is disassem bled b t 2 a FIGURE 5 Using a metal punch and a hammer disengage the selector fork 5 from piston cone 6 142 Dana Holding Corporation O ASM 0004E 112 Axle Service Manual DISASSEMBLY ia FIGURE 6 Using two wrenches lock piston 6 and remove nut 4 FIGURE 7 Remove screws 14 and remove the intermediate cover 13 NOTE Support the differential unit with a lever FIGURE 11 Remove guide ring 11 and o ring 10 NOTE The guide ring 11 and o ring 10 must be replaced each time the unit is disassemb
14. SJBAJ9JUI jio Anp 9520 ul 91 29 ZID IN 096 IN LSV IO TN OZ MEHM 10 ZION I8A8I 8281 5 0 Y 01 008 eoueuuoJed episino SIA SI 952916 1 Ajddns seoeyuns 10 Jo uoisoJ400 Aue JO Y92949 PIS M yedwod ION SJIO spiny LOG SAPPY AJON SID IN 10 ZID IN ajqevijdde JON SDUBPJODJE Ul ro Ajjnjaseo ue o ro Ajjnjaseo ue o dd IO IN 20 IN 1ueouqn ON uoJxeq UOIX9q IND 41v asn 490 HIP 9001 HHVS sexeJq SUOIJENJOB oi neJp u 104 G15 719 19 06 MO84VS 9 02 s4ee6 uo4xeq All IND 41W SOSIP 19 SIEGE G15 719 19 06 MO84VS 10 09 021 719 Idv OLLN ro Ajjnjoreo ue o 61 esn sexeJq 10 pue AIS POPU JI SMYVINAY S1D 14 06 M083VS 5 plodAu Apog G15 40 719 19 06 MO84VS 40 SY LIN AW 09 021 1e86 40 v19 Idv OLLN
15. PR LLIS 120 3x45 ZI 3 3 15 15 7 6 3 15 0648 094 5 2110 lt e LLI SPECIAL TOOLS P N 3317 3 P N 3739 T1 T2 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 106 SPECIAL TOOLS 3317 ASM 0004E 112 Axle Service Manual 100 10 40 20 20 2 5 Dana Holding Corporation 107 108 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 7 COMBINED BRAKE EXPLODED VIEW 109 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle NCAUTION Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Loosen and remove screws 5 and spring wa shers 6 Gradually loosen screws in a criss cross manner Leave two of the screws in place to hold cover in place to prevent it from falling FIGURE 1 Loosen nuts 31 and unfasten screws 32 in se quence Remove the front plug 1 to drain the residual lubricating oil NCAUTION Apply oil recovery tubes to the hydraulic connection points di ka j y E Wer 4 1 48 A
16. lt gt SPICER Off Highway Products service Manual Axle 112 ASM 0004E Rev 03 October 2015 5 INTRODUC FON i b aa a e d d 7 VERSION TRACKING i ea A A toni 8 SPECIFICATIONS iii 9 DEFINIKIONOF 9 DATA PLATE Leila 9 CONVERSION TAB wa T A 10 UNITS OF PRESSURE riale N A 10 NI OP WE rM 10 ARGUS 10 TORQUE SPECIFICATION Sy dd an at il 11 COARSE PUCH alleanza 11 L ER 11 WHEEL NUT TIGHTENING TORQUE G Rai 12 MAINTENANCE uil 13 MAINTENANCE POINTS a ille 13 JIL DRAINING MANDATORY PROCEDURE alia 14 ENTRAE HOW a Lm 14 PLANETARYT GEARREDUCHON blica 14 MAINTENANCE INTERVALS Ela 15 LUBRICANT amp SEALANT SPECIMGA HONG scsi rien 16 SAFETY PRECAUTIONS ii d MR 17 CHECKING WEAR AND REPLACING THE BRAKING DISCS 19 EXPLODEB VIEW M ili 19 Mg 20 ASSEMBLER adi R zn RAA ORA ea 22 SRECIRETOO0ES A Lc pL 24 EO 24 ON A AE O AA O O AA 24 PLANETARY REDUCTION AND AXLE SHAFT 25 EXPLODED VIEW sua um AE
17. 2305 jiem 1204 12020 x x 24 Dana Holding Corporation ASM 0004E 112 Axle Service Manual PLANETARY REDUCTION AND AXLE SHAFT EXPLODED VIEW ESR Ele e gt 9 16 Da 3 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 25 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 1 Remove the securing screws 1 from the spider cover 2 FIGURE 5 With the help of a puller remove the planetary wheel gears 12 NOTE Write down the assembly side of planetary wheels FIGURE 2 Disjoin the spider cover 2 from the hub 3 by al ternatively forcing a screwdriver into the appropriate slots mm l wi IE 5 _ _ Ba i 5 A e A 5 n v ln c 1 E 4 1 4 4 7 gt LI I gt A o i 1 4 i J la k m FIGURE 6 Using a puller for inner parts remove shim washer 13 from planetary cover 2 FIGURE 3 Remove the complete planetary carrier cover 2 26 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 10 Using a puller remove the complete crown flan ge 6 by acting on the stud bolts FIGURE 8 Loosen and remove the tightening nuts 5 from the crown flange 6
18. 5 pJepuejs Apog ees 104 SINVDIHAMI 949 99 JO KIH S8M JEWJON SUM 002 SUM 006 SUM 0001 AON3nO3tid sBuiusng seas SUM 001 SUM 001 XBW SUM 092 001 sbuueag palade JSSUM HHVS Aue Ji xoqdouq XEUJ SUM 096 001 SUM MO3HO 39NVHO 161 LNANLYVdINOD 6ulu luBi IIO IIO NOILVH3dO 15 Dana Holding Corporation ASM 0004E 112 Axle Service Manual LUBRICANT amp SEALANT SPECIFICATIONS LUBRICANT amp 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
19. DISASSEMBLY ti U z T Pani 4 M a 4 M FIGURE 7 Position wrench See drawing 49 onto FIGURE 10 Using a puller and a press remove the inner be the ring nut 7 and apply bar hold T2 See drawing T2 p 49 aring 9 from the pinion 8 to the pinion 8 Stop wrench T3 See drawing p 49 and rotate the pinion so as to release and remove the ring nut 7 NOTE If disassembly proves awkward heat the ring nut to ap proximately 80 C 4 FIGURE 11 Remove the thrust block of the external bearing 13 FIGURE 8 Apply blocks T4 See drawing T4 p 50 and with the help of a puller extract the pinion 8 complete with the in ternal bearing 9 the spacer 10 and shims 11 NOTE The thrust blocks of the bearings remain in the central body 12 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 39 DISASSEMBLY w FIGURE 12 Insert a drift inthe appropriate holes and remove the thrust block of the internal bearing 9 as well as the shim washers 14 FIGURE 13 ONLY IF NECESSARY Loosen and remove the screws 15 locking the support 16 Remove the whole support 40 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 17 Bring the internal bearing 9 complete with its FIGURE 14 ONLY IF HAS BEEN REMOVED thrust block under dial
20. Pinar n 2 1 Ta a ER FA i FIGURE 2 If the bearing needs replacing extract the bearing 3 and remove the crown 2 FIGURE 6 Insert tool T1 See drawing T1 p 128 between the planetary gears 7 FIGURE 3 Remove the shim washer 5 and the planetary gear 6 122 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY P FIGURE 7 Force tool T1 See drawing T1 p 128 in between the planetary gears 7 using two pin drivers Make sure that tool T1 See drawing T1 p 128 is perfectly lined up with the pins 9 when locked FIGURE 8 Place the differential carrier 12 under a press position guide bushing T2 See drawing T2 p 129 and insert press tool T3A See drawing T3 p 129 Press See dra wing T3 p 129 pin to limit position ASM 0004E 112 Axle Service Manual FIGURE 9 Remove press tool T3A See drawing T3 p 129 and guide bushing T2 See drawing T2 p 129 NOTE In this condition the tool T1 See drawing T1 p 128 con tains pin 9 FIGURE 10 Remove tool T1 See drawing T1 p 128 together with the pin 9 of the planetary gear Me FIGURE 11 Leave the released planetary gear in position and again lock tool T1 See drawing T1 p 128 Repeat the operations for the extraction of the pin of the 2nd planetary gear 9 Repeat the operations for all other pins
21. and lock it with screws 17 25 Torque wrench setting 104 128 N m The match marks on the two half boxes must correspond Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads 26 k FIGURE 31 If removed or missing assemble the swivel sle eve antirotation sleeve 16 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 189 ASSEMBLY FIGURE 32 Place the differential carrier under a press FIGURE 34 Heat the bearings 6 8 to about 100 C and fit Load the spring 27 and the coupling 28 it to the differential box 17 25 NOTE Pay attention to the slot position that fits the coupling 28 to the anti rotation key 6mm Wear protective garments when handling hot objects the FIGURE 35 If the bearings are replaced insert the external thrust blocks 6 8 in the middle cover 4 and in the central body 12 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 FIGURE 36 Insert a new o ring 25 on the centering diameter of the arm 190 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 37 Position the differential unit in the central FIGURE 39 Install the safety switch 1 complete with o ring body 12
22. bushing T2 See drawing T2 p 129 and fit the snap ring 11 position guide bushing T2 See drawing T2 p 129 and insert on the pin 9 the planetary pin 9 Make sure that the snap ring centers the seat and that it rests on the surface of the differential carrier Repeat the operations on the other planetary pins FIGURE 20 Put press tool See drawing T3 p 129 top of the planetary wheel pin 9 r LA FTH 1 T i FIGURE 23 Position the second planetary gear 6 in the dif ferential carrier 12 ke FIGURE 21 Press T3B See drawing T3 p 129 pin all the way down FIGURE 24 Position the shim washer 5 on the crown 2 NOTE In order to hold the shim washer 5 in position apply gre ase to it 126 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 25 Position the crown 2 on the differential carrier 12 and lock it with screws 1 applied with Loctite 242 Torque wrench setting for screws 128 142 N m NOTE Secure the screws using the criss cross method FIGURE 26 Install the bearings 3 and 4 using tool T4 See drawing T4 p 130 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 127 SPECIAL TOOLS SPECIAL TOOLS T1 P N 3708 128 Dana Holding Corporation 36 33 M26X1 5 r 22 5 10 5
23. fta a 166 SPECIAL TOOLS Lilli 170 ja 170 po LEE 171 Dom 172 deae DM au MM uM ORA 173 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 5 FLANGED PINION GEARBOX WITH FLOATING FLANGE 175 EE 175 DISASSEMBL dier c 176 YS suu crm 178 SPECIAL TOQOL Lille iena 179 i ER 179 RA ii W 180 AO 181 DIFFERENTIAL WITH BLOCK TO SPHERES 100 183 EXPLODED VIEW 183 DISASOBMBIEY idee u ere A A 184 ASSEMBEY agree ala iku te la innu dad dei 188 6 Dana Holding Corporation ASM 0004E 112 Axle Service Manual INTRODUCTION The efficiency and continued operation of mechanical units depend on constant correct maintenance and also on efficient re pair work should there be a break down or malfunction The instructions contained in this manual have been based on a com plete 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 photogra phs and diagrams illustrating the various phases of the operations allows accurate work to be performed All the information needed for correct disassembly checks and asse
24. sure that the cover is fitted with the oil discharge in the lo wer position If bearings are not new check the static torque if bearings are new check the continuous torque FIGURE 11 Lock the middle cover 5 with screws 4 Torque wrench setting for screw 23 8 26 2 Nem 58 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY RATIO RAPPORTO VERHALTNIS RAPORTE RAPPORT CLEARANCE GIOCO SPIEL JUEGO JEU FIGURE 14 Introduce a dial indicator with rotary key A FIGURE 17 Difference between MIN and MAX clearance for through the top plug hole 7 whole circumference should not exceed 0 09 mm Position the dial indicator on the center of one of the teeth of the crown pre set it to 1mm and reset it FIGURE 18 Apply Loctite 242 to the screws 3 fit them into one of the two holes and tighten FIGURE 15 Manually move the crown in both directions in Torque wrench setting 23 8 26 2 mE order to check the existing backlash between the pinion and Fit the top plug 7 after applying repositionable jointing com the crown pound for seals to the rims FIGURE 16 Adjust the backlash between the pinion and the FIGURE 19 Re install the complete arms crown by unloosing one of the ring nuts 1 and tightening the For details see CHECKING WEAR AND REPLACING THE opposite to compensate BRAKING DISCS p 19 Normal backlash see table ASM 0004E 112 Axle Service Manual
25. use a plastic hammer if ne cessary NOTE Make sure that the guard 4 is securely fastened onto the flange and that it is not deformed ASM 0004E 112 Axle Service Manual Dana Holding Corporation 47 SPECIAL TOOLS SPECIAL TOOLS TI P N 2308 T1A 0185592 0345323 250 1 135 0 5 245 48 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T2 P N 3317 3 n 0X15 0 8 SA on w 1 6 cO A g gt v Sa T zx 01 iN Fi O 24 191 Y x w 14 _ 94 T3 P N 3317 A DD i A Z 224 SF 2 ID 20 209 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 49 SPECIAL TOOLS T4 P N 2309 LO CN T5 P N 2310 0 001 030 2 5X45 gt 50 Dana Holding Corporation ASM 0004E 112 Axle Service Manual U lt e LL 6 3329 3 T6A ma ped pa IL 19 55H7 083 088 240 T6c T6B T6A T6C M18x1 5 e NV 105990500 LO Q 09596250259 25 4 DOK KX e OM PORA ONZ XXXXX XX 51 Dana Holding Corporation ASM 0004E 112
26. 139 position the second planetary gear 12 and relative shim wa sher 18 Dana Holding Corporation 135 ASSEMBLY zs gt FIGURE 19 Insert tool T1 See drawing in between the two planetary gears 12 Align the whole unit pushing bar T3C See drawing T3 p 139 in as far as it will go until press tool T3A See drawing T3 p 139 is expelled FIGURE 20 Lock tool T1 See drawing T1 p 138 behind the planetary gears 12 After locking the tool remove bar T3C See drawing T3 p 139 FIGURE 21 Fit snap rings 19 onto the pins 11 136 Dana Holding Corporation FIGURE 24 Press press tool T3B See drawing T3 p 139 as far down as it will go w FIGURE 22 Position the differential unit 9 under the press position bushing T2 See drawing T2 p 139 and insert the planetary pin 11 p a 7 gt FIGURE 23 Place press tool T3B See drawing T3 p 139 on top of the planetary pin 11 T 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 25 Remove press tool T3B See drawing T3 p 139 bushing T2 See drawing T2 p 139 and fit the snap 10 onto the pin 11 Make sure that the snap ring centers seat and positions it self on the differential unit face Repeat the operations on the other planetary pins FIGURE 26 Check that planetary have a light clearance in re lation to the first planetary gear Position
27. Connect the whole arm 8 to the hoist and put the rod under light tension Remove the whole arm for details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 Ney FIGURE 2 Draw out the screw 1 locking the washer 2 that stops the lever 3 66 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the braking disks 9 and the whole piston 10 For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 FIGURE 7 If pins 11 need replacing block the piston 10 into a vice whose jaws are covered in smooth material and re move the pins FIGURE 8 If thrust levers 12 and 13 need replacing remo ve the U joint 14 before removing the arms 8 For details see PLANETARY REDUCTION AND AXLE SHAFT p 25 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 67 ASSEMBLY ASSEMBLY FIGURE 12 Install the arms 8 into the main body check flat ness and block arms following the appropriate procedures il FIGURE 9 Install thrust levers 12 and 13 then install the lustrated in section HYDRAULIC NEGATIVE BRAKE p 149 U joint 14 For details see PLANETARY REDUCTION AND AXLE SHAFT p 25 FIGURE 13 Install the reduction bushing 6 complete with o ring 7 and block it with screws 5 Tighten screws with a tor que wrench setting of 23 8 26 2 N m FIGURE 10 Apply Loctite 270 to the threaded portion of the pins 11 a
28. Corporation 69 ASSEMBLY 70 Dana Holding Corporation ASM 0004E 112 Axle Service Manual EXTERNAL HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 71 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Release the pressure in the cylinder and discon nect the pressure delivery tube Remove the fulcrum pin 8 from the cylinder 4 complete with washers 12 FIGURE 1 Insert pressure into cylinder 4 in order to release the brakes NOTE If the machine hydraulic system cannot be used use an FIGURE 4 Remove ife cylinder assembly 4 complete with external manual pump rod 5 internal nut 6 and support 8 b 4 z z FIGURE FIGURE 5 Remove the snap ring 1 that checks the support 8 and remove the spacer 2 72 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY x Ls FIGURE 9 Install cylinder 4 complete with rod 5 and inter nal nut 6 FIGURE 6 Install spacer 2 and insert the pin of support 8 into the right hand braking lever Fi
29. Dana Holding Corporation 123 DISASSEMBLY L 288 rtm FIGURE 12 Remove tool T1 See drawing 1 128 and re move the last two planetary gears 7 the 2nd differential side gear 6 and the relative shim washer 5 from the differential Carrier 124 Dana Holding Corporation 5 0004 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 13 Insert the shim washer 5 and the differential side gear 6 in the differential carrier 12 f fe FIGURE 14 Position the shim washer 8 and the first plane tary gear 7 Hold them in position using bar T3C See drawing T3 p 129 E kt 2 4 pu FIGURE 15 With the help of press tool See drawing T3 p 129 position the second planetarv gear 7 and the relative shim washer 8 ASM 0004E 112 Axle Service Manual FIGURE 16 Insert tool T1 See drawing T1 p 128 between the two planetary gears 7 Line up the entire unit by pushing bar T3C See drawing T3 p 129 all the way down until press tool T3A See drawing T3 p 129 is ejected FIGURE 17 Lock tool T1 See drawing T1 p 128 behind the planetary gears 7 After locking remove bar T3C See drawing T3 p 129 FIGURE 18 Fit the snap rings 11 onto the pins 9 Dana Holding Corporation 125 ASSEMBLY a WIA LS FIGURE 22 Remove press tool T3B See drawing T3 p 129 FIGURE 19 Place the differential carrier 12 under the press
30. FIGURE 12 Assist the insertion of the piston 8 by lightly hammering around the edge with a plastic hammer FIGURE 10 Insert the stroke automatic regulation springs 15 place them in line with the piston 8 22 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 13 Fit the pin screws 10 making sure that they are FIGURE 15 Slightly lubricate the braking disks 6 and fit all of the same color them in the arm following the correct sequence orient them White 1 mm gap so that the oil circulation holes and the marks are perfect Yellow 0 75 mm gap ly lined up Blue 0 5 mm gap Apply Loctite 270 to the thread Torque wrench setting 5 N m cs i FIGURE 16 Check that the positioning of the sealing ring 16 on the arm is intact install the complete arm 2 Lock it into position using two facing screws 3 and washers FIGURE 14 Fit the reversal springs 7 on the piston 8 4 Pay attention not to deform the connections of the springs FIGURE 17 Check the flatness of the arms using tool T2 See drawing T2 p 24 and finally lock the arms with the screws 3 and the washer 4 using the criss cross method Torque wrench setting 298 N m ASM 0004E 112 Axle Service Manual Dana Holding Corporation 23 SPECIAL TOOLS SPECIAL TOOLS T1 P N 2313 W _ NA 25 110 25 160 T2 P N
31. GEARBOX VERSION If torque exceeds the maximum value then the size of shim S1 11 between the bearing 13 and the spacer 10 ne eds to be increased If torque does not reach the set value increase the torque setting of the ring nut 7 in different stages to obtain a ma value of 1000 N m If torque does not reach the minimum value then the size of shim S1 11 needs to be reduced When calculating the increase or decrease in size of shim S1 bear in mind that a variation of shim 11 of 0 01 mm corresponds to a variation of 60 Ncm in the torque of the pi nion 8 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 48 Apply Loctite 242 to the threaded part of the pi FIGURE 45 Lubricate the outer surface of the new sealing nion 8 Position tool T1A See drawing T1 p 48 or T1B and ring 6 and fit it onto the central body 12 using tool T9 See fasten it in order to avoid rotation Insert o ring 3 the nut 1 drawing T9 p 59 and tighten it using a torque wrench Torque wrench setting 280 310 N m FIGURE 46 Install the swinging support 5 FIGURE 49 Remove blocks 4 See drawing T4 p 50 used for extracting the pinion and re install the arms For details see CHECKING WEAR AND REPLACING THE Check that it is properly oriented BRAKING DISCS p 19 FIGURE 47 Fit the flange 2 complete with the guard 4 and fasten it For seating the flange 2
32. NEGATIVE BRAKE WITH QUICK RELEASE EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 75 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Remove the fulcrum pin 9 from the cylinder 4 complete with washers 22 FIGURE 1 Before starting any operation on the assembly di sable the cylinder by giving a light hammer blow to the exter nal ring of the check unit FIGURE 2 Remove snap ring 1 and extract spacer 2 FIGURE 5 Remove snap ring 5 from stem 6 and extract the check unit 7 76 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Remove snap ring 8 and washer 9 and separate FIGURE 9 Slowly release nut B and disassemble the check support 10 and second washer 9 from the check unit 7 unit A 1 FIGURE 7 Introduce an M14x100 screw A into the hole of FIGURE 10 Loosen nut 17 and remove stem 6 from the the check unit 7 and screw a nut B until the spring seat 11 cylinder 18 is moved to the end of stroke NOTE Use a hex bolt ix 7 FIGURE 8 Rotate snap ring 12 until ring ends match
33. ONLY Lock screws 31 in a criss cross method by using a torque wrench set to a maximum torque of 10 N m Do not exceed the specified torque setting ASM 0004E 112 Axle Service Manual Dana Holding Corporation 101 ASSEMBLY im 3 FIGURE 33 Lubricate seals 13 15 and fit the piston 12 FIGURE 36 Lubricate the o ring 24 and fit cylinder 18 into the cylinder 18 Engage piston on the pin 19 complete with piston 12 For the assembly use a plastic hammer and push the piston 12 to end of stroke FIGURE 37 Introduce screws 17 and tighten in a criss cross method use a torque wrench setting of 9 5 10 5 FIGURE 34 Lightly lubricate the braking discs 25 26 and fit them onto the hub 27 NOTE Before giving the final tightening align the external surfa ces of the components NOTE The braking discs pack starts and ends with steel discs 25 FIGURE 38 3 FUNCTION VERSION ONLY Using a plastic hammer push the piston 12 to the end of stroke ad FIGURE 35 Apply Loctite 510 on the face of the cover 23 Fit the discs hub cover assembly prepared in the previous stages onto the pinion and engage it 102 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 39 2 FUNCTION VERSION ONLY FIGURE 41 Check the state of the o ring 40 Fit the separating ring 10 of Belleville washers onto the cover Lubricate sealing ring 8
34. 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 0004E 112 Axle Service Manual Dana Holding Corporation 7 VERSION TRACKING VERSION TRACKING FILE NAME REVISION DATE CHANGES DESCRIPTION Added paragraph OIL DRAINING MANDATORY PROCEDU ASM 0004_eng_06072015 Rev 02 06 07 2015 REp 14 and updated paragraph SAFETY PRECAUTIONS Added new chapters PLANETARY REDUCTION 6 9 1617 FLANGED PINION TO GEARBOX WITH FLOATING ASM 0004E Rev 04 10 2015 Rev 03 23 10 2015 FLANGE p 175 and DIFFERENTIAL WITH BLOCK TO SPHERES 10096 p 183 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIFICATIONS DEFINITION OF VIEWPOINTS LEFT SIDE mi RIGHT SIDE LATO SINISTRO LATO DESTRO LINKE SEITE RECHTE SEITE LADO IZQUIERDO LADO DERECHO COTE GAUCHE COTE DROITE DATA PLATE O O SPICER CLARK HURTH MFG BY CLARK HURTH COMPONENTS S P A 38062 Arco Trento MADE IN ITALY 1 Type and model unit modification index 2 Serial number 3 Lubricant ASM 0004E 112 Axle Service Manual Dana Holding Corporation 9 CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE tt ET u I 10 Dana Holding Corpora
35. T1 See drawing T1 p 138 Repeat pin extraction operation on the second planetary pin 11 Repeat the same operations on the remaining pins FIGURE 13 Remove tool T1 See drawing T1 p 138 and ex tract from the differential unit 9 the two final planetary gears 12 the 2nd differential side gear 6 and the whole friction assembly concerned 7 194 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 14 Place the friction disc assembly 7 suitable for the specific type of slipping and differential side gear 6 into the differential unit 9 The composition of the unit is illustrated in the points below FIGURE 15 25 FRICTION UNIT COMPOSITION Friction ring with inner disc 13 intermediate discs 14 and friction discs 15 alternated outer disc 16 and spacer 17 As to 5 13 and 16 the side without notches must face outwards ASM 0004E 112 Axle Service Manual FIGURE 16 45 FRICTION UNIT COMPOSITION Friction ring with inner disc 13 intermediate discs 14 and friction discs 15 alternated outer disc 16 and spacer 17 As to rinos 13 and 16 the side without notches must face outwards FIGURE 17 Position shim washer 18 and the first planetary gear 12 Hold in position with bar T3C See drawing T3 p 139 Vu RZ amp 6 4 pA o FIGURE 18 Using press tool T3A See drawing
36. and unscrew studs 29 to retract the adjustment points 30 ONLY IF NECESSARY Remove points 30 NOTE Loosen studs 29 in an alternate manner until the piston comes to end of backstroke Dana Holding Corporation 97 DISASSEMBLY FIGURE 12 3 FUNCTION VERSION ONLY Loosen and remove the pin type screws 31 NOTE Loosen screws 31 in an alternate and criss cross me thod FIGURE 13 3 FUNCTION VERSION ONLY Remove springs 32 of piston 33 backward movement FIGURE 14 3 FUNCTION VERSION ONLY Slowly introduce compressed air through the connection point of the service brake to extract the piston 33 NCAUTION Hold piston 33 as it may be rapidly ejected and damaged 98 Dana Holding Corporation 4 a N MA E Td VAN go MU FIGURE 16 Remove sealing ring 38 from cover 8 NOTE Take note of direction of assembiv of ring 38 and replace ring everv time the unit is disassembled FIGURE 17 Remove sealing rings 13 and 15 and anti ex trusion rings 14 and 16 from the piston 12 Sealing rings 13 and 15 and anti extrusion rings 14 and 16 must be replaced each time the unit is disassem bled 5 0004 112 Axle Service Manual DISASSEMBLY FIGURE 18 3 FUNCTION VERSION ONLY Remove sealing rings 34 and 36 and anti extrusion rings 35 and 37 from piston 33 NOTE Sealing rings 34 86 and a
37. block of the external bearing 13 into its seat Disconnect the press and remove the tension rod NOTE Before starting the next stage make sure that the thrust block has been completely inserted into its seat FIGURE 21 Insert tool T7B See drawing T7 p 52 complete with external bearing 13 measurement ring T5 See drawing T5 p 50 and gauged ring nut T7C See drawing T7 p 52 Manually tighten 42 Dana Holding Corporation FIGURE 23 Lay bar T7A See drawing T7 p 52 on gauged nut T7C See drawing T7 p 52 and take the measurement at about 57 mm corresponding to the maximum diameter of arms centring 61 A 1 15 30 2 B FIGURE 24 Calculate size B which will be the first useful value for calculating the size of the shims 14 that are to be inserted under the thrust block of the internal bearing 9 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 25 Check the nominal size X marked on the pinion and add or subtract the indicated variation Y so as to obtain size Z e g Z 118 0 1 118 1 Z 118 0 2 117 8 C Z D FIGURE 26 Calculate size which represents the second value for calculating the size of the shims 5 that are to be placed under the thrust block of the internal bearing 9 B C S L R Se FIGURE 27 Calculate the difference between sizes B and C so as to obtain the size S of the shim 14 that will go under the thrust blo
38. support 14 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 85 ASSEMBLY FIGURE 20 Keeping to the following sequence install the flange 9 the o ring 10 and the nut 8 Apply Loctite 242 to the threaded portion of the pinion FIGURE 21 Install tool T1A See drawing T1 p 88 or T1B and tighten the nut 8 Torque wrench setting 280 310 FIGURE 22 Position the elastic compression bar set 7 NOTE Spring 18 and washer 19 which are part of the punch set must be installed at a later stage 86 Dana Holding Corporation FIGURE 23 Fix the positioning spring 5 and the cable 6 to the cam of the parking function FIGURE 24 Let the cable 6 slide into the guide and position the shoe set 3 by engaging the terminals in the regulation unit and in the cylinder te FIGURE 25 Insert the check springs 4 give a push anda torsion at the same time to engage hook A in the rear seat 5 0004 112 Axle Service Manual ASSEMBLY PA FIGURE 26 Move away the right shoe 3 and position the spring 18 and washer 19 of the elastic compression bar set 7 NOTE Check that the compression bar 7 is correctly inserted in the seats of the shoes 3 FIGURE 27 Engage the return springs 4 of the shoes 3 and hook them onto the upper bar 20 ASM 0004E 112 Axle Service Manual When reassembling the unit bleed the braking circuit and apply
39. the second differential side gear 6 and the second friction disc assembly 7 into the differential unit 9 ASM 0004E 112 Axle Service Manual FIGURE 27 Line the lubrication holes up with the slots in the differential carrier Orient the holes of the crown 4 towards the notches of the braking unit Position the crown 4 on the differential unit 9 and lock it with the screws 3 previously coated with Loctite 242 Torque wrench setting for screws 128 142 N m NOTE Tighten screws using the criss cross method FIGURE 28 If bearings 5 and 8 have been removed install them using tool T4 See drawing T4 p 140 FIGURE 29 Install the whole differential assembly 2 into the central body 1 For details see DIFFERENTIAL UNIT p 55 ud Dana Holding Corporation 137 SPECIAL TOOLS SPECIAL TOOLS T1 P N 3708 138 Dana Holding Corporation yoy Y j Y M26X1 5 da jie 1x45 5 0004 112 Axle Service Manual SPECIAL TOOLS 24 5 X 0 0 1 x S gt 18 9 P 5 hs T2 P N 3424 sa Q N 8 Sy 08 T3 P N 2306 T3A 7 5 5 ep CN x Q a 10 _ 46 45701 56 6 T3C 030 1x30 1 9
40. the unit is disassembled ASM 0004E 112 Axle Service Manual Dana Holding Corporation 111 DISASSEMBLY FIGURE 12 Place the negative brake cylinder unit 13 under a press and extract the intermediate disc 16 by applying pressure to the internal collar of the piston FIGURE 13 Using a plastic hammer extract the piston 15 from the cylinder 13 FIGURE 14 Remove o rings 17 19 and anti extrusion rings 18 20 from the piston 15 NOTE The snap rings 17 19 and anti extrusion rings 18 20 must be replaced each time the unit is disassembled 112 Dana Holding Corporation minimum 2 9 mm FIGURE 15 Whatever the reasons for disassembling the bra ke unit always check the thickness of the braking discs 23 If shim A of just one disc 23 is close to the minimum ad missible size of 2 9 mm replace the entire pack 5 0004 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 16 Fit the o rings 27 29 and the anti extrusion rings 28 80 onto the piston 26 NOTE Carefully check the assembly position of rings 28 30 E FIGURE 17 Lubricate the seals and fit the piston 26 into the braking unit 35 NOTE 1 Keep the oil throughways vertical 2 Ensure that the adjusting screws 32 are recessed in relation to the piston 26 touch down plane FIGURE 19 Using bar push the piston 26 the end of it
41. to damage the snap ring 10 5 FIGURE 36 Using tool T3 See drawing T3 p 35 fit shim wa sher 13 into planetary cover 2 FIGURE 34 Cross tighten the nuts 5 in two stages Initial torque wrench setting 130 N m Final torque wrench setting 255 285 N m FIGURE 37 With the help of tool T4 See drawing T4 p 36 insert the planetary wheel gears 12 into the cover 2 Accurately check the orientation 32 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 38 Lock the gears 12 into position by fitting the snap rinos 11 M a a Check that the o ring 18 is in good condition and in posi tion I d l 4 dt E i V N b L bn 6 FIGURE 40 Lock the planetary carrier cover 2 by tightening the screws 1 Torque wrench setting for screws 40 50 N m 5 0004 112 Axle Service Manual Dana Holding Corporation 33 SPECIAL TOOLS SPECIAL TOOLS T1 P N 3354 0158 5 0 08 05 0 12 2200 2003 0148 TIMKEN 0150 34 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T2 P N 3502 240 2139 50 0153 5x15 T3 P N 2321 Proteggere da 1 cementazione 30 XXXXXXX XXX 9 9 O ASM 0004E 112 Axle Service Manual Dana Holding Corporation 35 SPECIAL TO
42. with the help of a bar and fit the middle cover 4 2 torque wrench setting maximum 30 N m If necessary adjust differential unit clearances see DIFFE RENTIAL UNIT p 55 Install the top cap and the arms For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 FIGURE 38 Lock the middle cover 4 with screws 3 Torque wrench setting for screw 23 8 26 2 N m FIGURE 40 Re install the complete arms For details see CHECKING WEAR AND REPLACING THE Use only new screws pre treated with Driloc locking adhe BRAKING DISCS p 19 sive Threads must be cleaned from oil Degrease only non pre treated threads ASM 0004E 112 Axle Service Manual Dana Holding Corporation 191
43. 112 Axle Service Manual Dana Holding Corporation 175 DISASSEMBLY DISASSEMBLY FIGURE 3 Remove the sealing ring 5 FIGURE 1 Disjoin the entire reduction unit 1 from the axle and place it on a bench FIGURE 4 Position wrench T1 See drawing T1 p 179 onto the ring nut 4 and apply bar hold T2 See drawing T2 p 180 to the pinion AXLE SIDE Stop wrench T1 See drawing T1 p 179 and rotate the pinion FIGURE 2 Using an extractor disassemble the floating slange so as to release and remove the ring nut 4 sleeve 3 if the removal result difficult using an air heater heat up the floating flange sleeve 3 to a maximum temperature of 100 C and remove Before to disassemble the ring nut is needed to remove the caulks Wear protective garments when handling hot objects NOTE If the pinion the bearings or other parts must be repla NOTE ced refer to the chapter BEVEL PINION p 37 Carefully clean the shaft splines from Loctite residue Check the shaft splines do not have wear signs 176 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 1 GEARBOX SIDE Remove the floating flange sleeve 1 from gearbox output shaft NOTE If disassembly proves awkward heat the ring nut to ap proximately 80 C Check the shaft splines do not have wear signs NOTE Carefully clean the shaft splines from grease residue ASM 0004E 112 Axle Service Manual
44. 8 and fit flange 5 into the cover 8 8 measure size B and write it down Measure size A which you will need for calculating the shims 9 according to the following S A B 18 4 where S Shim thickness 18 4 mm fixed measure of Belleville washers FIGURE 42 Fit the Belleville washers 11 onto the cover 8 thoroughly checking washers orientation FIGURE 40 Lightly lubricate the shims 9 required according to calculations and the separating ring 10 of the Belleville washers Fit shims and ring on the cover 8 NOTE Position the larger shim so that it leans against the cover FIGURE 43 Lubricate the o ring 40 and install the cover as sembly 8 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 103 ASSEMBLY FIGURE 44 Fit screws 6 and washers 7 lock the cover with a torque wrench setting of 116 128 N m NOTE Tighten in an alternate and criss cross method FIGURE 45 Apply Loctite 242 to the threaded portion of the pinion fit o ring 4 and nut 3 tighten the nut with a torque wrench set to 280 310 N m NOTE Use tools T2 See drawing T2 p 106 T3 See drawing T3 p 107 104 Dana Holding Corporation gt i i es FIGURE 47 3 FUNCTION VERSION ONLY Connect the service and negative brakes to an external pump introduce pressure up to a value of 20 25 N m NOTE Check that pressure is kept stable for at le
45. Axle Service Manual SPECIAL TOOLS T7 P N 2312 jie N PET Y LO ARA Tee 20 _ _ 0110 M14x1 T7B JE s Nilo LO LO LI 041 203 o O LO 06 5 A T8 P N 3354 59 x oO a a A Q 2 3 5 S x 5 e Y 52 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T9 P N 3327 100 LO Y 28 2 LO 22 e LO 3x15 Y Y 26 1O 75 SEZIONE A A ASM 0004E 112 Axle Service Manual n20 H7 n80 Dana Holding Corporation 53 54 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DIFFERENTIAL UNIT EXPLODED VIEW Dana Holding Corporation 55 DISASSEMBLY DISASSEMBLY FIGURE 4 Apply tool T1 See drawing T1 p 60 and remove the ring nuts NOTE Accurately clean the threaded portions on ring nuts of body and cover FIGURE 1 Remove the complete arms For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 FIGURE 5 Remove the capscrews 4 from the middle cover 5
46. Dana Holding Corporation 177 ASSEMBLY ASSEMBLY NOTE ONLY IF PREVIOUSLY DISASSEMBLED If the pinion the bearings or other components must be installed and adjusted refer to the procedure FIGURE 2 Apply Loctite 270 to the thread of the ring nut 4 and screw the nut onto the pinion Apply special wrench T1 See drawing T1 p 179 to the ring nut 7 and bar hold T2 See drawing T2 p 180 to the pinion 8 Lock the wrench T1 See drawing T1 p 179 and rotate the pi nion using a torque wrench up to a minimum required torque setting of 900 1000 N m Using a calking tool calk the ring gear collar in the provided holes paying attention to do not cut the collar FIGURE 3 Assemble the centering tool T3B see drawing p 182 on the ring nut 4 lubricate the sealing ring 4 in ner lip and assemble it on the special tool T3A see drawing p 181 Install in its seat 178 Dana Holding Corporation FIGURE 4 AXLE SIDE As shown in the picture using Loctite 648 coat the inner spli nes of the sleeve 3 and the pinion spline Assemble the floating flange sleeve onto the pinion FIGURE 5 GEARBOX SIDE Using specific grease NLG 2 or 3 carefuly coat the output shaft splines Assemble the floating flange sleeve 2 onto the gearbox output shaft FIGURE 6 The reduction unit was attached to a sling during dismantling Install the entire reduction unit ASM 0004E 112 Axle Service Ma
47. Dana Holding Corporation 59 lt e LLI SPECIAL TOOLS T1 P N 3333 123 100 125 A 238 T2 P N 3317 4 38x1 25x29 DIN 5480 59 _ 14 30 EH O75 0 08 255 0 12 Tornito 32 25 5x15 35 60 15 48 AM 11 4 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 60 MANUAL EMERGENCY RELEASE EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 61 RELEASE RELEASE Before maintaining brakes when the axle is installed ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle M FIGURE 3 Using a wrench tighten the screws 31 in an al ternate sequence by 1 4 turn at a time so as to compress the Belleville washers 1 and disengage the braking disks Tighten maximum by one turn FIGURE 1 Loosen nuts 80 of screws 31 provided for the mechanical and manual release of the braking units then move the nuts backwards by approximately 8 mm FIGURE 2 Tighten screws 31 so as to fasten them onto the pressure plate 23 62 Dana Holding Corporation ASM 0004E 112 Axle Servi
48. ELEASE FIGURE 37 To release the negative brake in an emergency loosen the 3 check nuts 33 Tighten the screws 34 until they are fixed to the piston tighten further in a gradual and alternate manner by a maxi mum of 1 5 turns FIGURE 38 When emergency is over loosen the screws 34 in a gradual and alternate manner until the value of 27 mm is restored Lock screws in position with the nuts 33 tightened to a tor que of 15 N m ASM 0004E 112 Axle Service Manual Dana Holding Corporation 117 SPECIAL TOOLS SPECIAL TOOLS T1 P N 2308 61 5 61 5 73 85 97 126 12 118 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T2 P N 3317 3 ASM 0004E 112 Axle Service Manual 9 HGL QIWOL 087S LXBE GLO Dana Holding Corporation 119 120 Dana Holding Corporation ASM 0004E 112 Axle Service Manual NORMAL DIFFERENTIAL UNIT EXPLODED VIEW Dana Holding Corporation 121 ASM 0004E 112 Axle Service Manual DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 4 If the bearing need replacing extract the bearing 4 from the differential carrier 12 uo D 2 FIGURE 5 Remove the snap rings 11 from the two pins 9 of the planetary gears 7 mn TRU An
49. IGURE 2 Remove the check screws 3 of the crown 4 NOTE Write down the position of the niches of the central hole in relation to the protrusions of the friction unit steel di SCS FIGURE 5 If bearing 8 needs replacing extract it from the differential unit 9 132 Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the snap rings 10 from the pins 11 of FIGURE 9 Place the differential unit 9 under a press posi the planetary gears 12 tion guide bushing T2 See drawing T2 p 139 and insert press tool See drawing T3 p 139 Press press tool See drawing T3 p 139 to end of stroke FIGURE 7 Introduce tool T1 See drawing T1 p 138 in between the planetary gears 12 FIGURE 10 Remove press tool See drawing 139 and bushing T2 See drawing T2 p 139 NOTE In this state the pin 11 is contained within tool T1 See drawing T1 p 138 FIGURE 8 Using two pin drivers engage tool T1 See dra wing T1 p 138 in between the planetary gears 12 FIGURE 11 Remove tool 1 See drawing 11 p 138 and pla netary pin 11 with it Carefully check that tool T1 See drawing T1 p 138 keeps in an aligned position with the pins 11 when locked ASM 0004E 112 Axle Service Manual Dana Holding Corporation 133 DISASSEMBLY FIGURE 12 Leaving the released planetary in its position lock again tool
50. M 0004E 112 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P N 3543 T2 P N 2316 ASM 0004E 112 Axle Service Manual Proteggere da 15 cementazione 028 058 024 088 gt M12x125 18 35 17 0162 5 NIA 0 2 0 1 Dana Holding Corporation 147 148 Dana Holding Corporation ASM 0004E 112 Axle Service Manual HYDRAULIC NEGATIVE BRAKE EXPLODED VIEW LA GO 5 es 26 LIL 27 70 lt 2 291 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 149 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 15 30 Bar FIGURE 4 Connect an external pump to the union piece P1 of the negative brake and introduce a pressure of 15 30 bar to eliminate the pressure of the Belleville washers 2 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 in jury If fluid is injected into the skin it is necessary to seek immediate medical care FIGURE 2 Sling the arm to be removed and connec
51. NING MANDATORY PROCEDURE p 14 Indicates an imminently hazardous situation which if not avoided will result in death or se rious injury Indicates an imminently hazardous situation which if not avoided could result in death or se rious injury 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 0004E 112 Axle Service Manual Dana Holding Corporation 17 18 Dana Holding Corporation ASM 0004E 112 Axle Service Manual CHECKING WEAR AND REPLACING THE BRAKING DISCS EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 19 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 Perform all operations on both arms 4 N L 4 w E 1 a i umm lt ak 1 H AT 4 82 WW S gt dii a l gt i a 8 2 EN f i s b 4 j ate p y d 1 RZ gt IL i D A p u Prz FIGURE 3 Loosen and remove the screws 3 and the wa shers 4 that fix the arm 2 to the central body 5 Ls arpi i FIGURE 4 Remove the arm 2 together with the pack of the braking disks 6 Place the arm on a bench S FIGURE 2 Apply the brakes and keeping them under pres su
52. OLS T4 P N 2304 2x15 Q T5 P N 2322 10 1 5x45 Proteggere da cementazione lt OOO 2525255 SK 5 KS 555555 36 Dana Holding Corporation ASM 0004E 112 Axle Service Manual BEVEL PINION EXPLODED VIEW 0 2 5 MON 5 QNT x 2 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 37 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 4 gt a 7 4 g 4 ne f N 1 l XN j E l 2 v 4 A lt i P I lt La l 7 7 i 4 mi x 4 l L D i is f lt am gt x vw s FIGURE 3 Position tool T1A See drawing T1 p 48 or T1B so as to avoid pinion rotation Loosen and remove the nut 1 also remove the o ring 3 unit For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 and DIFFERENTIAL UNIT p 55 FIGURE 4 Remove the flange 2 complete with guard 4 by means of a puller I FIGURE 2 If disassembly is awkward heat the check nut 1 of the flange 2 at 80 C NOTE Heating is meant to loosen the setting of Loctite on the nut 1 qo NN 4 YA 4 R 4 La 7 IN i x FIGURE 5 Remove the swinging support 5 38 Dana Holding Corporation ASM 0004E 112 Axle Service Manual
53. URE 26 3 FUNCTION VERSION ONLY Measure size A1 of piston 12 and write it down FIGURE 24 Fit the sealing rings 13 15 and the anti extru sion rings 14 16 onto the piston 12 of the negative brake NOTE Carefully check the assembly position of the anti extru sion rings FIGURE 27 3 FUNCTION VERSION ONLY Fit the separating ring 10 of Belleville washers onto the cover 8 measure size B1 and write it down 100 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY 5 4 FIGURE 30 3 FUNCTION VERSION ONLY FIGURE 28 3 FUNCTION VERSION ONLY Insert springs 32 for piston 33 backward movement Using the measurements just taken calculate thickness S of shims 9 as follows S A1 1 5 B1 18 4 where S Shim thickness 1 5 mm fixed measure of braking discs clearance 18 4 mm fixed measure of Belleville washers FIGURE 31 3 FUNCTION VERSION ONLY Apply Loctite 242 to the thread of screws 31 and tighten NOTE FIGURE 29 3 FUNCTION VERSION ONLY Tighten the screws with a normal wrench in an alternate Lubricate the o rings and install the whole piston 33 Orient and criss cross method the piston with the help of a lever and push it to end of stroke with a plastic hammer Check that the adjusting stakes 30 are thoroughly inserted and make sure they perform a sliding motion in relation to each other 1 FIGURE 32 3 FUNCTION VERSION
54. URE 41 STANDARD INPUT FLANGE VERSION Apply onto the pinion 8 the bar hold and with the help of a torque wrench check the torque of the pinion 8 Torque 120 200 STANDARD INPUT FLANGE VERSION If torque exceeds the maximum value then the size of shim S1 11 between the bearing 13 and the spacer 10 ne eds to be increased If torque does not reach the set value increase the torque setting of the ring nut 7 in different stages to obtain a ma ximum value of 570 N m If torque does not reach the minimum value then the size of shim S1 11 needs to be reduced When calculating the increase or decrease in size of shim 51 bear in mind that a variation of shim 11 of 0 01 mm corresponds to a variation of 60 Ncm in the torque of the pi nion 8 FIGURE 42 FLANGED GEARBOX VERSION Apply Loctite 270 to the thread of the ring nut 7 and screw the nut onto the pinion 8 46 Dana Holding Corporation P ad ta ji FIGURE 43 FLANGED GEARBOX VERSION Apply special wrench T3 See drawing T3 p 49 to the ring nut 7 and bar hold T2 See drawing T2 p 49 to the pinion 8 Lock the wrench T3 See drawing T3 p 49 and rotate the pi nion using a torque wrench up to a minimum required torque setting of 900 N m FIGURE 44 FLANGED GEARBOX VERSION Apply onto the pinion 8 the bar hold and with the help of a torque wrench check the torque of the pinion 8 Torque 120 200 Ncm FLANGED
55. all the crown flange 14 to the crown wheel 13 and lock in position with the snap ring 15 Use only new nuts pre treated with Driloc locking adhesive Threads must be cleaned from oil Degrease only non pre treated threads ASM 0004E 112 Axle Service Manual Dana Holding Corporation 167 ASSEMBLY FIGURE 32 Grease seal ring 23 and sealing face of axle FIGURE 35 Using tool T4 See drawing T4 p 173 fit shim shaft 16 washer 4 into planetary cover 3 Install the axle shaft 16 making sure it is properly engaged in the braking disks and in the differential unit FIGURE 36 Using a caking tool calk the edge of the shim washer 4 seat as shown in picture FIGURE 33 Gradually release the pressure and remove the idraulic fitting FIGURE 37 With the help of a driver insert the first bearing 8 into the cover 8 FIGURE 34 Install the sun gear 10 Fit the planetary gear 7 onto the satellite gear cover 3 and insert the second bearing 6 using a driver 168 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 38 Lock into position the planetary gears 7 with the FIGURE 40 Fit the planetary carrier cover 3 onto the hub snap rings 5 18 Pay attention to the correct snap ring 5 assembling Install the snap rings 5 with the worked side facing the be arings Personal injury can result when installing snap ring The appropriate safety equipment
56. ast 5 minutes and make sure there are no leaks FIGURE 48 3 FUNCTION VERSION ONLY Screw studs 29 until pins 30 position themselves against the piston 33 then unscrew studs by one turn to obtain a 1 5 mm stroke Lock studs 29 into position with the nuts 28 tightened at 15 N m Helease pressure 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 49 Check negative brake release by introducing a pressure of 16 35 bar and by manually rotating the flange 5 Release pressure 0 8 1 2mm FIGURE 50 Fit the electronic sensor 1 and screw it up to the limit stop Unscrew sensor by 3 4 turn and lock into position with nut Locking torque maximum 30 N m Do not exceed the specified torque setting FIGURE 51 To release the negative brake during an emer gency lack of pressure due to vehicle breakdown loosen nuts 22 and screw studs 21 in an alternate and gradual manner until you notice some preloading continue by giving another 1 5 turns ASM 0004E 112 Axle Service Manual 17 mm TM gt A A JT 1 E FIGURE 52 When the emergency is over loosen the studs in an alternate manner until a 17 mm projection is obtained lock into position with the nuts 22 tightened to 15 Dana Holding Corporation 105 38x1 25x29 DIN 5480 975 3 55 958 O 5x45 ZZ AAAA ROKK KK OO 59565520262 00099000009 110 140 5
57. ce Manual ADJUSTMENT ADJUSTMENT Tecno Lube 104 3 IM d 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 m i FIGURE 5 Adjust screws 31 to obtain a distance of 34 0 5 mm between axle machined surface and screw underhead FIGURE 6 Lock into position with nuts 30 Hold screws 81 into position while locking the nuts 30 af ter locking check the distance of screws 31 once more ASM 0004E 112 Axle Service Manual Dana Holding Corporation 63 64 Dana Holding Corporation ASM 0004E 112 Axle Service Manual MECHANICAL PARKING BRAKE EXPLODED VIEW g e ASM 0004E 112 Axle Service Manual Dana Holding Corporation 65 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Remove washer 2 lever 3 and o rings 4 Mark the positions of levers 3 in relation to the thrust levers 12 and 13 FIGURE 1 Though the photos in this manual refer to a stee ring and oscillating axle the operations described apply any way FIGURE 5
58. ck of the internal bearing 9 ASM 0004E 112 Axle Service Manual FIGURE 28 Insert shim S 14 and the thrust block of the internal bearing 9 in the central body NOTE To hold shim S 14 in position apply grease FIGURE 29 Position tool T6A See drawing T6 p 51 and ten sion rod T6C See drawing T6 p 51 Connect the tension rod to the press fasten the thrust block and then remove the tools NOTE Before going on to the next stage make sure that the thrust block has been completely inserted Dana Holding Corporation 43 ASSEMBLY P FIGURE 30 Position tools T7C See drawing T7 p 52 and T7B See drawing T7 p 52 complete with tapered bearings 9 and 13 manually tighten until a rolling torque has been obtained FIGURE 31 Insert the stem of a depth gauge DDG in either side hole of tool T7C See drawing T7 p 52 reset the gauge with a presetting of approximately 3 mm FIGURE 32 Remove the depth gauge and release tools and bearings from the central body Re install all and insert the spacer 10 between bearings 9 and 13 manually tighten the whole pack 44 Dana Holding Corporation gt e ad hA e OL FIGURE 33 Insert depth gauge DDG into tool T7B See drawing T7 p 52 T7C See drawing T7 p 52 and measure variation H in relation to the zero setting performed back at figure 28 H 0 12 70 13 51 FIGURE 34 The variation i
59. d 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 14 Dana Holding Corporation ASM 0004E 112 Axle Service Manual lt gt TT mi O lt lt 2 TT lt L MAINTENANCE INTERVALS AJISOOSIA pue sjubougnj ozu 10 6 200 ASd 28S d SOL T S9v S 19 IdV 761 6L 26 SISPOLU 5 95 e eg PIOdAH ST 10 IdV 06 MSZ AVS pis 4 02 OLLN AJISODSIA M SjIO esn 9 0Z P 1 JO 9522 uj SJBAJ9JLI esiou Jejeuo SIUBWOJJAU9 JO 9522 U paljdde
60. dle cover 4 Check the state of the o ring 5 184 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 7 If the bearings 6 8 need replacing extract the FIGURE 9 Using a press load the spring 27 and the swivel external thrust blocks of the bearings 6 8 from middle cover sleeve 28 4 and central housing 12 FIGURE 10 Pull off the coupling 28 and the spring 27 FIGURE 8 If the bearing needs replacing extract the bea rings 6 8 from the differential carrier 17 25 Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to If disassembly is carried out in order to replace crown wheel eyes wear eye protection equipment and pinion bearings or planetary gear break up distance washers and calculate clearances as indicated in the sec tions regarding removal disassembly assembly and instal lation of differential unit and bevel pinion FIGURE 11 Remove the blocking balls 26 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 185 DISASSEMBLY FIGURE 12 Remove the fittin screws 14 15 of the crown FIGURE 15 Remove the shim washer 18 and the planetary 16 gear 19 Note the position of assembly FIGURE 16 Remove shafts 22 complete with satellite gears 20 and spherical shoulder washers 21 FIGURE 14 Using a plastic hammer disjoin
61. e o ring 9 FIGURE 11 Loosen and remove the nuts 11 from the crown flange 25 pressur 6 bar Maximum actuating the brake to lock the bra ke discs in position NOTE If during removal of the nuts 11 the studs 24 got loose replacement is needed ASM 0004E 112 Axle Service Manual Dana Holding Corporation 163 DISASSEMBLY FIGURE 15 Disassemble the sun gear centering ring 22 and seal ring 23 from the arm FIGURE 13 Remove the crown flange 25 assembly Mark the assembly position of the crown gear carrier flange FIGURE 16 Harness the wheel hub 18 14 Partially extract the hub 18 using an extractor Remove the external bearing 17 FIGURE 14 Remove the snap ring 15 from the crown 13 Remove the crown flange 14 FIGURE 17 Remove the complete hub 18 164 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 18 Remove the thrust blocks 17 19 from the bea rings by forcing a puller into the appropriate slots on the hub NOTE Avoid damaging or deforming of the thrust blocks FIGURE 20 Remove snap ring 20 from the arm The seal ring may not be reused ASM 0004E 112 Axle Service Manual Dana Holding Corporation 165 ASSEMBLY ASSEMBLY FIGURE 21 Assemble the new studs 24 in the arm and tighten to a torque of 35 50 NOTE Assemble the Driloc pretreated stud 24 portion toward the arm Use only new s
62. e piston 10 into the cylinder 7 NOTE Lightly hammer all around the edge in an alternate sequence FIGURE 19 Using a plastic hammer insert the piston 8 into the cylinder 7 NOTE Lightly hammer all around the edge in an alternate se quence FIGURE 22 Apply grease and position the Belleville washers 2 and engage the cylinder 7 NOTE FIGURE 20 Fit o rings 9 and 8 onto the piston 10 Check the sense of direction of washers 7 and relative Lubricate the piston and the o rings and install the unit into centering the cylinder 7 154 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 23 Apply grease and position the Belleville washers 2 and engage the cylinder 1 NOTE Check the sense of direction of washers 2 and relative centering FIGURE 27 Tightening the studs with a torque wrench set to a torque of 30 45 N m FIGURE 28 Fill with ATF oil For details see MAINTENANCE INTERVALS p 15 FIGURE 25 Position the Belleville washers 2 and engage the cylinder 7 NOTE Check the sense of direction of washers 2 and relative centring ASM 0004E 112 Axle Service Manual Dana Holding Corporation 155 ASSEMBLY 3 1 1 F 3 l E P i h 4 w j L i FIGURE 29 Connect external pump to the negative brake and introduce pressure to 15 30 bar Loctite 270 Always check tha
63. e 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 DRAI
64. ers 6 and the screws 5 FIGURE 28 With the help of a punch fit the snap ring 9 into the cover 7 N m NOTE Carefully check the orientation of the snap ring 9 AC AUTION 2 Tighten the by tightening the screws gradually and criss cross method FIGURE 29 Fit the external 11 and internal 10 reversal springs of piston 15 into the seats of the cover 7 FIGURE 32 Lubricate the snap ring 9 and fit the flange 4 and the o ring 8 Apply Loctite 242 to the tang of the pinion and fit the nut 2 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 115 ASSEMBLY FIGURE 33 Tighten the check nut m of the flange 4 with a torque wrench set to 280 310 NOTE Use tool T2 See drawing T2 p 119 t ry lt FIGURE 34 Fit the drain plug 1 and with a torque wrench tighten to a maximum torque of 15 N m Do not exceed the specified torque FIGURE 35 Connect the connection e of the service brake and negative brake to an external pump and introduce a pressure of 20 30 bar FIGURE 36 Adjust the service brake stroke by tightening the screws 32 up to a maximum torque of 10 N m until they are fixed to the piston 26 Unscrew by 7 faces of the hexagon equivalent to 2 mm and secure with the nuts 31 tightening to a torque of 15 5 0004 112 Axle Service Manual 116 Dana Holding Corporation RELEASE R
65. he sealing ring 16 into its seat FIGURE 22 Position the upper part of tool T1B See drawing T1 p 34 and press the thrust blocks into the hub 3 all the way down 30 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 26 Lubricate the outer face of the sealing ring 10 and with the help of tool T5 See drawing T5 p 36 fit it in the arm NOTE Accurately check direction of assembly 6 in the crown 15 NOTE Carefully check that ring 14 is properly inserted in the FIGURE 27 Lubricate with grease the sealing ring 16 and slot of the crown 15 the hub of the arm 9 Install the hub 8 24 2 ct EZ mJ ma A wy m A e FIGURE 31 Fit the complete crown flange 6 FIGURE 28 Install the external bearing 8 NOTE NOTE In order to fasten the flange 6 use a plastic hammer and Usinga plastic hammer divethe bearingio the limitstop alternately hammer on several equidistant points by lightly hammering around the edge ASM 0004E 112 Axle Service Manual Dana Holding Corporation 31 ASSEMBLY FIGURE 32 Apply Tecnolube Seal 101 grease to the surface FIGURE 35 Grease snap ring 10 and sealing face of axle of the safety flange 7 which touches the crown flange 6 shaft 4 Fit the safety flange 7 Install the axle shaft 4 making sure it is properly engaged in the braking disks and in the differential unit NOTE Be very careful not
66. indicator Fit support 16 including o ring 20 onto the intermediate Determine overall thickness D of the bearing checking the body discrepancy between this size and the size of the measure ment ring NOTE The cavity located on the outer diameter must face up wards Check and lubricate the o ring 20 Press the thrust block in the center and take several measu rements while rotating the thrust block FIGURE 15 Fasten support with screws 15 previously coa ted with Loctite 270 Tighten using the criss cross method to a tightening torque a d of 90 100 N m FIGURE 18 Partially insert the thrust block of the external be aring 13 FIGURE 16 Using a surface plate reset a dial indicator DG and place it on the measurement ring T5 See drawing T5 p 50 with a thickness of 30 2 mm Preset the dial indicator to approximately 2 mm ASM 0004E 112 Axle Service Manual Dana Holding Corporation 41 ASSEMBLY FIGURE 19 Install tension rod T6C See drawing T6 p 51 measurement ring T5 See drawing T5 p 50 and front guide tool T6A See drawing T6 p 51 on the thrust block of the ex ternal bearing 13 FIGURE 22 Fit a dial indicator DG1 with long stem into bar T7A See drawing T7 p 52 when the bar rests on two size blocks GB of 57 mm reset the gauge Preset the gauge to approximately 2 mm and reset FIGURE 20 Connect the tension rod to the press and move the thrust
67. ing surface of the flange 7 and fit it onto the pinion 11 FIGURE 11 Install the caliper unit 2 and secure with screws 1 coated with Loctite 242 FIGURE 8 Apply Loctite 242 to pinion thread Fit o ring 6 Tighten using a torque wrench to a tightening torque of 302 and nut 5 334 N m ASM 0004E 112 Axle Service Manual Dana Holding Corporation 91 SPECIAL TOOLS SPECIAL TOOLS T1 P N 2308 01 05 02 NINE 125 15 125 034 5 19 gt 050 135 0 5 61 5 61 5 73 85 97 126 12 92 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T2 P N 3327 74 660 680 040 5x45 3x15 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 93 94 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 4 INCOMING BRAKE 2 AND 3 FUNCTION VERSIONS EXPLODED VIEW VARIANT FOR 2 FUNCTION VERSION VARIANTE PER 2 FUNZIONI VARIANTE FUR 2 FUNKTIONEN VARIANTE POR 2 FUNCIONES VARIANTE POUR 2 FONCTIONS D Q BS 4 OM 3 FUNCTION VERSION ONLY SOLO PER VERSIONE A 3 FUNZIONI NUR FUR AUSFUHRUNG MIT 3 FUNKTIONEN SOLO POR VERSION A 3 FUNCIONES SEULEMENT POUR VERSIONS A 3 FONCTIONS ASM 0004E 112 Axle Service Manual Dana Holding Corporation 95 DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on ve hicle follow all safety instructions in the Original Equi
68. install tool T2 See drawing T2 p 147 FIGURE 17 Install bearing 16 onto the differential carrier 17 NOTE Make sure that the bearing is well set in the differential carrier ASM 0004E 112 Axle Service Manual Dana Holding Corporation 145 ASSEMBLY dd 4 4 i Ep t FIGURE 21 Screw tool T2 See drawing T2 p 147 on the th FIGURE 24 Install the intermediate cover 13 and lock it with read of the piston 6 to compress the spring 7 and vacate screws 14 Tighten screws using a torque wrench setting of the seat for installing the snap ring 12 23 8 26 2 im Carefully check the state of the o ring 23 B FIGURE 22 Install the snap ring 12 Remove tool T2 See drawing T2 p 147 and fit the snap ring 9 of spring 7 FIGURE 25 Install the lock nut 4 of the selector fork 5 and lock it with a torque wrench set to a torque of 70 75 N m FIGURE 23 Insert the selector fork 5 and the differential unit N 15 into the central unit 22 mao Engage the selector fork 5 in the coupling 19 and on the pi FIGURE 26 Install the security switch 2 complete with o ring ston 6 torque wrench setting maximum 30 If necessary adjust differential unit clearances see DIFFE RENTIAL UNIT p 55 Install the top cap 1 and the arms For details see CHE CKING WEAR AND REPLACING THE BRAKING DISCS p 19 146 Dana Holding Corporation AS
69. led FIGURE 8 Disconnect selector fork 5 from piston 6 While holding the selector up remove the differential unit 15 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 143 DISASSEMBLY FIGURE 12 Remove snap ring 9 and take piston unit 6 apart Remove all component parts FIGURE 13 Remove bearing 16 from the differential carrier 17 as well as the stop ring 18 the sleeve 19 and the sphe res 20 NOTE Write down the direction of assembly of the stop ring 18 FIGURE 14 ONLY IF NECESSARY Remove the key 21 and disassemble the differential unit 15 For details see DIFFERENTIAL UNIT p 55 144 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 18 Fit o ring 10 and guide ring 11 onto the piston 6 Lubricate seals and insert the assembly into tool T1 See FIGURE 15 ONLY IF PREVIOUSLY DISASSEMBLED drawing T1 p 147 Assemble the differential unit 15 For details see DIFFERENTIAL UNIT p 55 Position the key 21 in the differential unit 19 FIGURE 19 Insert tool T1 See drawing T1 p 147 in the cen tral unit 22 and push the piston 6 into the seat Remove tool T1 See drawing T1 p 147 FIGURE 16 Install soheres 20 sleeve 19 and stop ring 18 NOTE Pay great attention to ring orientation 18 FIGURE 20 Install spring 7 and washer 8 on the piston 6 i and
70. ly 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 INCLUDE IN EACH SERVICE MANUAL SHOWS THE TORQUE FIGURE RELATED TO THE BOLT CHARACTERISTIC ONLY DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8 8 amp 10 9 STUD MATERIAL QUALITY 10 9 ALLOW TIGHT TORQUE M18 x 1 5 mm M18 x 1 5 Nem 442 489 M20 x 1 5 mm M20 x 1 5 613 677 N m M22 x 1 5 M22 x 1 5 822 908 N m THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST RELATED ON STUD MATERIAL QUALITY DANA AXLE ARE 10 9 ONLY 12 Dana Holding Corporation ASM 0004E 112 Axle Service Manual MAINTENANCE MAINTENANCE POINTS n fmm b 1 1 1 I l t S zd discs dii 2 dili ji dili 2 1 Oil filling plug 2 Oil draining plug 3 Check level plug Dana Holding Corporation 13 ASM 0004E 112 Axle Service Manual OIL DRAINING MANDATORY PROCEDURE OIL DRAINING MANDATORY PROCEDURE e Do attempt any maintenance if the axle is hot 40 50 104 122 F Hot oil and components can cause personal in jury Avoid skin contact Wear protective gloves and glasses e Make sure all fluids are contained during inspection maintenance tests adjustment an
71. mbly 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 fol lowing 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 equip ment 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 en crusted 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 crown wheel and pinion shafts and sealing parts o rings oil shields which are subject to major stress and wear In any case it is advisable to replace the seals every time a component is overhauled or repaired During assembly the sealing rings must be lubricated on the sealing edge In the case of the crown wheel and pinion replacement of one component requires the replacement of the other one During assembly the prescribed pre loading backlash and torque of parts must be maintained
72. must be worn To avoid injury to your eyes wear protective glasses during this procedure FIGURE 41 Lock the planetary carrier cover 8 by tightening the screws 2 Torque wrench setting for screws 35 50 N m FIGURE 39 Insert a new o ring 9 on the centering diameter of wheel hub NOTE FIGURE 42 Install the oil filling plug 1 and washer In order to hold the o ring 9 in position apply grease to orque wrench setting 35 50 it Fill with appropriate type and quantity of oil ASM 0004E 112 Axle Service Manual Dana Holding Corporation 169 O I lt e LLI SPECIAL TOOLS TI ACCOPPIARE CON RALLA TIMKEN JP12010 GIUOCO RADIALE 0 15 0 25 oF LX OL 0 169 5 0163 035 22 040 H7 n6 gt lt 030 ez ZN 0 08 050 0 12 77 ACCOPPIARE CON RALLA TIMKEN JP12010 GIUOCO RADIALE 0 15 0 25 660 38 3788 169 5 163 Cot 0 095 050 7 272772222222 LLL LLLA 0 155 0 160 2200 003 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 170 SPECIAL TOOLS
73. nd fit them onto the piston 10 Block them torque wrench setting 30 35 N m n a Le FIGURE 14 Install in sequence the lower o ring 4 the lever 3 and the washer 2 with the relative o ring 4 Block with screw 1 and tighten using a torque wrench set ting of 23 8 26 2 N m FIGURE 11 Re install the piston 10 and the braking disks 9 For details see HYDRAULIC NEGATIVE BRAKE p 149 Refer and keep to the positions marked during disassembly 68 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 15 Connect the braking circuit and apply maximum working pressure to set the disks Release the pressure loosen nut 15 and unscrew stud 16 by a few turns FIGURE 16 Apply a force of 8 10 N 0 8 1 kg to lever 8 Direct the force towards the braking direction in order to eli minate the idle stroke While the force is being applied tighten stud 16 until it is caused to rest onto reduction bushing 6 uen n L t 7 a g a y M A A A LETS ESR FIGURE 17 Lock stud 16 in this position with nut 15 Torque wrench setting 20 25 The idle stroke should be eliminated without preloading thrust levers 12 and 13 FIGURE 18 After connecting the control cable check that when brakes are released both studs 16 do lean against bu shing 6 ASM 0004E 112 Axle Service Manual Dana Holding
74. ng 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 oxi dation 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 16 Dana Holding Corporation ASM 0004E 112 Axle Service Manual 5 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 th
75. nter the hole of the fulcrum FIGURE 20 Lock nut 17 in position against the stem of the pin 3 piston 23 Apply Loctite 242 to the thread of the fulcrum pin 3 screw Torque wrench setting for the nut maximum 40 N m and tighten pin with a torque wrench set to 25 30 N m Jw FIGURE 21 m the pressure and cheek that piston 23 FIGURE 18 Check that a clearance A is left between the le returns and stops in a position where it projects out from the ver 28 on the cylinder side resting against the adjustment cylinder head 4 by 4 5 mm stud and cylinder 18 If necessary remove the lever turn it by one tooth in relation to the spline and repeat idle stroke elimination procedure ASM 0004E 112 Axle Service Manual Dana Holding Corporation 79 ASSEMBLY FIGURE 22 Release the check unit 7 by giving a hammer blow to the external ring Introduce pressure again and check that at the end of piston stroke the check unit 7 is actually engaged onto the rod 6 80 Dana Holding Corporation 5 0004 112 Axle Service Manual INCOMING DRUM BRAKE EXPLODED VIEW M 20 T ri
76. nti extrusion rings 35 37 must be replaced each time the unit is disassembled A min 1 36 mm FIGURE 19 Always check the thickness of braking discs 26 even if the braking unit is being disassembled for other rea sons than this If thickness A of one of the discs 26 is close to the mini mum admissible size of 1 36 mm replace the whole pack FIGURE 20 BRAKING DISCS PACK CONTENTS The braking discs pack is comprised of 11 braking discs and 12 steel counterdiscs ASM 0004E 112 Axle Service Manual 46 A FIGURE 21 If the braking discs unit is replaced shims 9 which determine the preloading of Belleville washers 11 must to be restored FIGURE 22 ONLY WHEN REPLACEMENT IS NECESSARY Remove the union pieces 41 and 42 connecting the lubri cation tube 2 NOTE During the assembly stage union pieces 41 and 42 must be coated with Loctite 577 and tightened to a torque wrench setting of 35 50 N m Dana Holding Corporation 99 ASSEMBLY ASSEMBLY FIGURE 25 Lubricate sealing ring 38 and using tool T1 See drawing T1 p 106 fit it into the cover 8 FIGURE 23 3 FUNCTION VERSION ONLY Fit the sealing rings 34 36 and the anti extrusion rings 35 NOTE 37 onto the piston 33 of the service brake Carefully check the direction of ring 38 NOTE Carefully check the assembly position of anti extrusion rings m c 4 775 FIG
77. nual SPECIAL TOOLS SPECIAL TOOLS T1 P N 3317 3 38x1 25x29 DIN 5480 075 255 0 12 Tornito 32 25 A 3p i Q015H7 n6 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 179 SPECIAL TOOLS T2 P N 3317 A 100 2 5 180 Dana Holding Corporation ASM 0004E 112 Axle Service Manual SPECIAL TOOLS T3A n115 n90 n64 5 307 SEZIONE A A ASM 0004E 112 Axle Service Manual Dana Holding Corporation 181 SPECIAL TOOLS da adattare al magnete utilizzato 182 Holding Corporation ASM 0004E 112 Axle Service Manual DIFFERENTIAL WITH BLOCK TO SPHERES 100 EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 183 DISASSEMBLY DISASSEMBLY FIGURE 4 Insert a screwdriver in the opposing slots then for ce and remove the middle cover 4 and the complete diffe FIGURE 1 Remove the complete arms rential unit For details see CHECKING WEAR AND REPLACING THE BRAKING DISCS p 19 FIGURE 2 Remove the security switch 1 FIGURE 6 Extract the complete differential unit 7 FIGURE 3 Remove the capscrews 3 from the mid
78. on 159 160 Dana Holding Corporation ASM 0004E 112 Axle Service Manual PLANETARY REDUCTION 6 9 EXPLODED VIEW 161 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY DISASSEMBLY Perform all operations on both arms d P FIGURE 3 Disjoin the planetary cover 3 from the hub by al ternatively forcing a screwdriver into the appropriate slots Remove the complete planetary carrier cover 3 FIGURE 1 Remove the drain plug 1 with washer and drain oil Make sure all fluids are contained during inspection main tenance tests adjustment and repair of the product Prepa re a suitable container to collect the fluid before removing any component containing fluids Dispose of all fluids fol lowing legal and local regulations FIGURE 4 Remove snap rings 5 Hot oil and components can cause personal injury Avoid skin contact Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to eyes wear eye protection equipment FIGURE 2 Remove planetary cover screws 2 FIGURE 5 Remove the planetary gears 7 and bearings 6 8 162 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Using a puller for inner parts remove shim washer FIGURE 9 Remove the complete axle shaft 16 4 from planetary cover 9 FIGURE 7 Use a screwdriver to remove th
79. owly introduce low pressure compressed air through the connection member for the service brake in or der to extract the piston 10 Hold the piston 10 back as it may be suddenly ejected and damaged NOTE The o rings must be replaced each time the unit is disas sembled a w 1 gt FIGURE 11 Move the cover 7 outwards FIGURE 14 Write down their order of assembly and mark and remove negative piston FIGURE 12 Remove the Belleville washers 2 and write down direction of assembly 152 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 15 Slowly introduce low pressure compressed air FIGURE 17 Remove braking discs 16 and shims 24 wri through the connection member for the negative brake in or ting down direction of assembly der to extract the piston 3 NOTE If disks are not to be replaced avoid changing their posi tion Hold the piston 3 back as it may be suddenly ejected and damaged FIGURE 16 Remove brake discs 14 and 15 writing down direction of assembly NOTE If disks are not to be replaced avoid changing their posi tion ASM 0004E 112 Axle Service Manual Dana Holding Corporation 153 ASSEMBLY ASSEMBLY FIGURE 18 Fit o rings 4 28 27 5 6 onto the piston 3 Lubricate the piston and the o rings and install the unit into the cylinder 7 FIGURE 21 Using a plastic hammer insert th
80. pment Manufacturer OEM manual that came with the vehicle Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 14 FIGURE 3 Remove nut 3 o ring 4 and flange 5 NOTE If disassembly is awkward heat nut 3 at about 80 FIGURE 4 Loosen screws 6 in an alternate and criss cross method until the action of Belleville washers 11 becomes null Remove screws 6 and spring washers 7 of cover 8 FIGURE 2 Loosen the two nuts and remove lubrication tube 2 FIGURE 5 Pull out cover 8 shims 9 separating ring 10 and Belleville washers 11 NOTE Take note of the assembly direction of shims 9 and Bel leville washers 11 96 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Slowly introduce compressed air through the nega tive brake connection point in order to extract the piston 12 Hold piston 12 as it may be rapidly ejected and damaged FIGURE 8 Remove cylinder 18 complete with guide pin 19 of piston 12 NOTE Take note of direction of assembly ASM 0004E 112 Axle Service Manual FIGURE 9 With the help of a lever pry off the cover 23 com plete with o ring 24 NOTE Thoroughly clean the face of bevel pinion support where the hub rests check the o ring 24 and replace it if ne cessary y Pa FIGURE 11 3 FUNCTION VERSION ONLY Loosen nuts 28
81. re check the linings S between the disks using tool T1 See drawing T1 p 24 Minimum S 4 5 mm FIGURE 5 Remove the braking disks 6 and write down their order of assembly Replace the braking disks and the intermediate disks on both sides if necessary NOTE 1 If the disks do not need replacing avoid switching their position 2 Extract the axle shaft 9 20 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the reversal springs 7 from the piston 8 FIGURE 8 Slowly introduce compressed air through the con nection of the braking circuit in order to extract the entire pi NOTE ston If the springs 7 are weak or deformed they must be re placed FIGURE 7 Remove the pin screws 10 guiding the piston 8 See MECHANICAL PARKING BRAKE p 65 HYDRAULIC NEGATIVE BRAKE p 149 If the screws are to be replaced write down the different co lors for the different brake gaps ASM 0004E 112 Axle Service Manual Dana Holding Corporation 21 ASSEMBLY ASSEMBLY kl a m i FIGURE 11 Lubricate the seals 11 12 and fit the piston 8 into the arm 2 FIGURE 9 Accuratelv clean the piston 8 and the seats of slide and seal Replace the o rings 11 and 12 and the anti extrusion rings 13 and 14 make sure that the assembiv side is correct Accuratelv check the positioning of the anti extrusion rings 13 and 14
82. s stroke FIGURE 20 Remove the two screws 24 used as guides Apply Loctite 242 to the thread of screws 24 fit the springs 25 and screw them in an alternate and criss cross method Tighten with a torque of 10 15 N m ASM 0004E 112 Axle Service Manual Dana Holding Corporation 113 ASSEMBLY FIGURE 21 Fit the o rings 17 19 and the anti extrusion rings 18 20 the piston 15 NOTE Carefully check the assembly position of rings 18 20 FIGURE 22 Lubricate the seals and fit the piston 15 in the cylinder 13 Push it to the end of its stroke with the help of a plastic hammer FIGURE 23 Heat the intermediate disc 16 at about 120 C and install it on the piston 15 by centering tooth D in the slot of the cylinder 13 114 Dana Holding Corporation UM _ WEE UAI i a A TT x h KE FIGURE 25 Install the braking discs 22 23 on the coupling 21 by starting with a steel disc 22 Eu NOTE Before assembling lubricate the friction discs 23 with oil a s _ d install the cylinder FIGURE 26 Lubricate the o ring 14 an 13 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 27 Fix the cylinder 13 with the screws 12 tighte FIGURE 30 Lubricate the seal 8 and fit the cover unit 7 ning to a torque of 9 5 10 5 N m onto the cylinder 13 as well as the snap wash
83. s to be added to a set value of 0 12 0 13 mm so as to obtain the size of shim S1 11 which will be inserted between the external bearing 13 and the spacer 10 and subsequently to determine the preload for the bearings FIGURE 35 Position the internal bearing 9 and the pinion 8 under a press force the bearing onto the pinion 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 36 Fit the pinion 8 shim S1 11 and spacer 10 FIGURE 39 STANDARD INPUT FLANGE VERSION in the main body 12 Apply Loctite 242 to the thread of the ring nut and screw the nut onto the pinion 8 NOTE The thinner shims must be placed in between the thicker ones 2 A aa t j ELM VE m FIGURE 40 STANDARD INPUT FLANGE VERSION Apply special wrench T3 See drawing T3 p 49 to the ring nut 7 and bar hold T2 See drawing T2 p 49 to the pinion 8 Lock the wrench See drawing p 49 and rotate the nion using a torque wrench up to a minimum required torque setting of 500 N m FIGURE 37 Insert the external bearing 13 in the central body in order to complete the pack arranged as in the figure FIGURE 38 Connect the pinion 8 to the tie rod T8A See drawing T8 p 52 and T8B See drawing T8 p 52 connect the tie rod T8C See drawing T8 p 52 to the press and block ASM 0004E 112 Axle Service Manual Dana Holding Corporation 45 ASSEMBLY P uu AA ICI VOI FIG
84. slot 6 4 Remove snap ring 12 ASM 0004E 112 Axle Service Manual Dana Holding Corporation 77 ASSEMBLY ASSEMBLY r FIGURE 11 Screw stem 6 into the piston without locking the nut 17 FIGURE 12 Assemble the check unit 7 by inverting the steps followed in the disassembly procedure FIGURE 13 Using a plastic hammer install the check unit 7 onto the stem 6 78 Dana Holding Corporation FIGURE 14 Fit the safety snap ring 5 onto the stem 6 NOTE In case the braking disks have been replaced or if brake pistons have been removed before adjusting the negati ve braking unit apply the brakes several times at maxi mum pressure in order to set clearances FIGURE 15 Loosen nuts 26 and apply a force of 8 10 N 0 8 1 kg to levers 28 Direct the force towards the braking direction to eliminate the clearances by using studs 27 lock nuts 26 to a torque wrench setting of 20 25 N m The idle stroke should be eliminated without causing any preloading 5 0004 112 Axle Service Manual ASSEMBLY FIGURE 16 Fit the spacer 2 and insert the pin of support FIGURE 19 Introduce pressure into the cylinder 4 and with 10 in the right hand braking lever the levers 28 resting against the adjustment studs 27 Fit the snap ring 1 screw rod 6 to engage the quick release 7 in the slot d U a FIGURE 17 Rotate stem 6 to ce
85. t it to a hoist Loosen and remove screws 17 150 Dana Holding Corporation FIGURE 3 Remove arm together with brakes and axle shafts lay down the arm vertically fa 1 FIGURE 4 Gradually release the pressure in the braking cir cuit bringing it to zero through the external pump Do not remove any part of the hydraulic circuit without ha ving completely released the hydraulic pressure The removal of pressurized parts or loss caused from relea sing these components can cause serious injuries and even death A leak from a hole of the size of a pin can cause se rious injury If fluid is injected into the skin it is necessary to seek immediate medical care 5 0004 112 Axle Service Manual DISASSEMBLY 11 CAUTION If the screws are to be replaced write down the different co lors for the different brake gaps Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake 9 Down p m a FIGURE 8 Write down the order of assembly and remove the counterwasher 11 4 FIGURE 6 Remove the reversal springs 12 from cover 11 FIGURE 9 Loosen the studs and remove two of them ASM 0004E 112 Axle Service Manual Dana Holding Corporation 151 DISASSEMBLY i jg FIGURE 10 Loosen studs and remove two of them FIGURE 13 Sl
86. t the hydraulic circuit test for leaks under pressure Always use cardboard or panel to control the loss A leak from a hole of the size of a pin can cause serious in jury If fluid is injected into the skin it is necessary to seek immediate medical care e FIGURE 33 Apply LOCTITE 270 to the thread of the pistion adjustment nut Tighten with torque wrench setting of 10 15 N m FIGURE 30 Insert the stroke automatic regulation springs 19 place them in line with the piston 11 Y BRAKE GAP FIGURE 34 Y brake gap 0 5mm 1 00mm 1 25mm 1 50mm Depending on axle configuration FIGURE 31 Insert the intermediate disk 11 156 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY 5 7 Loctite 270 FIGURE 35 Fit the pin screws making sure that they are all of the same color Apply Loctite 270 to the thread Torque wrench setting 5 7 N m U FIGURE 36 Take the measurement from the surface of the intermediate disk to the cover sealing surface with 30 bar of pressure introduced EXAMPLE 25 4 mm FIGURE 37 the brake disc pack including the shim under a press load with 1000 kg and take the measure V EXAMPLE V 40 mm ASM 0004E 112 Axle Service Manual S 68mm x y v FIGURE 39 S 68 mm x v Thickness of shims to insert under the shim washer Dana Holding Corporation 157 ASSEMBLY
87. t the second spacer 2 and snap ring 1 y U 4 1 1 Kms 1 Ru s l dar FIGURE 10 Center the hole of fulcrum pin 3 and washers 12 Apply Loctite 242 to the pin thread screw and tighten pin FIGURE 7 Apply Loctite 270 to the rod 5 and screw itinthe with a torque wrench set at 25 30 N m piston 13 as far as it will go p 4 P hu z ul 1 d ri 1 kata ZEN WE lt Maj FIGURE 11 Introduce pressure into the cylinder 4 and while FIGURE 8 Loosen nuts 17 and set braking levers 19 clea holding both levers 19 back against the adjusting screws rances to zero by turning studs 18 lock nuts 17 with a tor 18 move nuts 6 and 7 so that they are made to rest que wrench setting of 20 25 N m against support 8 lock the nuts with a torque wrench setting of 50 60 N m Clearances should be set to zero without causing any pre loading ASM 0004E 112 Axle Service Manual Dana Holding Corporation 73 ASSEMBLY FIGURE 12 Check that when the brakes are released pres sure inserted levers 19 lean against the screws 18 without pre stressing them and make sure that a clearance A is left between cylinder 4 and lever 19 Also check that when pressure is released piston 13 projects out by 4 5 mm 74 Dana Holding Corporation ASM 0004E 112 Axle Service Manual EXTERNAL HYDRAULIC
88. the brakes several times when the machine is not in motion so as to obtain the automatic adjustment of shoes 3 clearance Dana Holding Corporation 87 SPECIAL TOOLS SPECIAL TOOLS T1 P N 2308 126 73 97 61 5 85 12 88 Dana Holding Corporation 5 0004 112 Axle Service Manual BEVEL PINION SUPPORT EXPLODED VIEW ASM 0004E 112 Axle Service Manual Dana Holding Corporation 89 DISASSEMBLY DISASSEMBLY FIGURE 3 Loosen and remove the nut 5 and the o ring 6 NOTE If necessary apply tool T1A See drawing T1 p 92 or tool T1B to the flange 7 so as to prevent pinion rotation FIGURE 1 Loosen screws 1 and remove caliper unit 2 NOTE Access to screws 1 is gained through the holes on the disk 3 FIGURE 2 Loosen the nuts 4 and remove the disk 3 Remove the screws 19 FIGURE 5 Remove the seal ring 9 90 Dana Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 9 Apply tool T1A See drawing T1 p 92 T1B to _ the flange 7 tighten nut with a torque wrench FIGURE 6 After tightening the ring nut 5 lubricate the outer Torque wrench setting 280 310 surface and using tool T2 See drawing T2 p 93 fit the seal ring 9 into the support 13 FIGURE 10 Install disk 3 and keep it into position with screws 19 and nuts 4 FIGURE 7 Lubricate the seal
89. the half box 17 FIGURE 17 Remove the shim washer 24 and the planetary 25 gear 23 NOTE Note the coupling marks 186 Dana Holding Corporation ASM 0004E 112 Axle Service Manual DISASSEMBLY FIGURE 19 Slowly introduce compressed air via the diffe rential lock inlet to extract the piston 10 Work carefully as the piston may be expelled rapidly FIGURE 20 Remove seals 11 from the arm NOTE All seals must be replaced every time the unit is disas sembled Particular attention must be paid not to damage the seats of both seals and piston slide ASM 0004E 112 Axle Service Manual Dana Holding Corporation 187 ASSEMBLY ASSEMBLY FIGURE 24 Insert planetary gear 23 together with shim wa sher 24 FIGURE 25 Install the satellite gears 20 and spherical shoulder washers 21 onto the shafts 22 and place into the FIGURE 22 Install the piston 10 assembly differential housing 25 Tap lightly with a mallet to seat the piston 10 completely NOTE Note the assembly position FIGURE 26 Insert planetary gear 19 together with shim wa sher 18 FIGURE 23 Apply Loctite 270 to the threaded portion of the guide screws 10 Torque wrench setting 14 16 N m 188 Holding Corporation ASM 0004E 112 Axle Service Manual ASSEMBLY FIGURE 27 Assemble the half boxes pieces 17 25 FIGURE 29 Position the crown 16 on the differential carrier
90. tion ASM 0004E 112 Axle Service Manual TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT mewo O E Weximm is irnn fis wanm 161 _20Nm fas manm jsswwm or wonm __ __ _ __ 200_22 Nm aer aan mecnm _ 200 221Nm ero zum _ S7I AION _ MiO mm 2 fes senm fiss sisnm _ 900 451 Nm seoor nm _ 660_790Nm Mae mm jes senm srs sosum jer senm _ e08 08Nm fera vena _ 1040 1104 TO MSO mm 475 1ez nm iora 2082505 Wm 2200 282010 2408 2757 Nm FINE PITCH SIZE OF BOLT TYPE OF BOLT sesterzi io esnemezeus _ rasstocwezio MG 257 285 Nm 23 senm Nm 125mm fss sisnm s52 6Nm rs menm stam w TeNm metum ec _ je sim usnm Nm aozenn mecs 29 _260Nm _
91. 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 cle arance ranging between 0 1 and 0 25 mm LOCTITE 648 Anaerobic adhesive for fast and medium strength gluing of cylindrical metal joints nub on shaft Can glue together parts with radial clearance below 0 1 mm AREXONS REPOSITIONABLE JOINTING COMPOUND FOR SEALS Solvent based seali
92. tuds 24 pretreated with Driloc locking adhesive Threads must be cleaned from oil Degrease only non pretreated threads FIGURE 22 Position the upper part of tool T1 See drawing T1 p 170 and press the thrust blocks 17 19 into the hub 18 at end of stroke FIGURE 23 Assemble the inner tapered roller bearing 19 in the hub 18 FIGURE 24 Position the sealing ring 20 in the special tool T2 See drawing T2 p 171 Position tool T2 See drawing T2 p 171 and press the sealing ring 20 into its seat NOTE Ensure the ring 20 is correctly oriented The flat surface should be visible after mounting FIGURE 25 Install the wheel hub 18 ASM 0004E 112 Axle Service Manual 166 Dana Holding Corporation ASSEMBLY k k ka FIGURE 26 Install the inner bearing 17 FIGURE 29 Install the complete crown flange 25 assembly In order to fasten the flange 25 use a plastic hammer and NOTE alternately hammer on several equidistant points Using a plastic hammer drive the bearing to the limit stop by lightly hammering around the edge FIGURE 27 Assemble centering ring on the special tool T3 see drawing T3 p 172 lubricate the seal ring lips 23 and assemble on the special tool T3 then assemble them in the arm W L A hs o FIGURE 31 Tighten the nuts 11 in two stages using the criss cross method Final torque wrench setting 255 285 N m FIGURE 28 Inst

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