DANA Transaxle / Hilliard Gearbox Parts Breakdown 4WD
Contents
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3. Note A list of all available service kits and components can be found on the exploded view drawing on next page 2 0 9 H 6E0 4 E029 9 17 EM pt ursa aiu tata DIAYIS AT FT Nenen SHE LEV DaN gt 0 SNLYLS N I Ci 8 has SNDISIA3d 8 NOTLdTAOS30 aly 00 Y FT TAS a ONY ASIA 4 1 3g er 1 MOLING ISNSHL EA 2v39 5 Op 1 ATGHASSY CMA 39V vi 279 1 1 X VIOSI L Ts 1 SNIN D 8 OH JOS 9Tld LE 1 W39 NOINId 1 X X WIS 110 EE WALPXOBXOB IYSBAW 1 SNISNOH 207 1 9779 NIYO 2113 0 ZE 1 ANANI vi dIU H 0E yl 62 1 ayan 1 311d N3ADO ZZ 1 1 91165 X00604 XOIOES ONIHSNB 52 1 t3 g0t8 0 6 2 029 INANI
4. 31IN SI p SONY aNDDOT M 82 2N1 81 81 8 m EO F22 la ED 328 j 58 EL E ZE SI L 5 0080 SSLSWVIO Nid ZE S 8 1 SNId DNLANSYAM NIW 8880 WN NIW Eg Nid AE BELO CTH 8130 WS a SS3NDOTHL ew DL CLH 2813 PSI NIN 998 SALAMYIO SONIM 0529077 CIWS WS NIN 288 SHISAVIO Wand 5 10 CIH 815 WSJ Bb 13 0 218188 SALINYIO 5 199815 SALANYIO E SAW 1818987 2BISAVIO 35 8 ANIN SY 3 ONY 38155394 1816 B3ISAVIO L SSVI 1 12345 114 3015 104 13113 EE B E Hild INTIS me T HAAL 30 72 FEAT 30 ENN 5551 1258 ISNY VIVO NIGIS ANG VIRES S Y 8 2 a j 3 H Please contact our Customer Service Department 866 646 5278 To special order DANA Transaxle Parts Key No DANA Part No gt 012CH345 X 012CH317 012LK133 012HH122 012GV164X 012SV118X 012HH128 012 381 1 012 380 1 070HM282 070HM130 1 840293 012HD106 500024 6 012WD129 X 012WD130 X 34617 070HN218 012HN127 012SR170 1 012HM132 1 012WA123 012HU137X 012HM110 1 012HM110 2 012HN120 41356 012HN140 012HP120 585965 012GS307 012LK134 012HD111 012HD129 012HS121 012HS126 012HS125 01265202 01265302 01265337 012GS204X 01265215 012GS207X 012HR128 585994 01265216 012 0
5. bottom of page 2 Assembly Procedure To Reassemble the Gearcase follow the procedure listed below 1 2 lt 10 11 12 13 14 Reassemble the oil fill plug part 37 into the gearcase assembly part 28 and torque to 10 ft lbs 16 Be sure that all parts are clean and free of any dirt or debris and all residual oil has been removed Check the condition of the square sectioned o ring located on the large output cover part 7 Make sure that it is clean and free of any cuts or nicks It is recommended that this part is replaced whenever the unit is taken apart Place the thrust button part 41 back into the 4 hole located on the protruding boss on large cover plate part 27 Place the thrust plate part 13 on top of the same boss Press the race output hub with the 4 male dowel pin part 17 back into the large cover part 27 Set the armature plate part 19 back onto the coil part 26 located in the large cover plate part 27 The tangs of the armature plate should face out from the cover Place the nylatron plastic shim plate part 40 on top of the armature plate and install the retaining ring part 8 back into the slot located on the large cover part 27 Insert the small needle roller bearing part 6 onto the 4 dowel on the race output hub Reassemble the clutch housing ring gear Part 12 the roll cage part 39 and the 14 rollers part 38 Insert the assembled clutch fro
6. entire circumference If you feel the coil above the pole faces replace the large output cover P N 6203 12 100 If the coil is fully below the pole faces continue on to step 5 Clean and inspect the internal clutch components Slowly remove the roll cage part 39 from the clutch housing ring gear part 12 Using a clean dry lint free cloth clean the 14 clutch rollers part 38 the 2 race output hubs parts 16 amp 17 and the internal profile in the clutch housing ring gear part 12 If there are any excessive scratches nicks or deep flats present on any of these parts replace with the proper service kit listed at the bottom of page 4 Problem 4WD will not disengage 1 Check the armature plate part 19 for a consistent wear pattern and flatness To do this completely drain the oil from the unit by removing the drain plug part 32 located on the bottom of the gearcase with a 5 16 hex key wrench Collect the oil and dispose properly Remove the 7 hex head bolts part 2 from the large cover using a 4 socket Set the unit on a flat surface with the large output cover part 27 facing up Carefully lift the large cover straight up off of the gearcase Remove the clutch housing ring gear part 12 out of the gearcase be sure to hold the roll cage with the clutch housing ring gear to prevent the cage from falling out Remove the retaining ring part 8 out of the large cover and then remove the nylatron shim p
7. 07 PET NE NId JOI N SLYW EZ 1 v51 c0 SIcT yc NIYE 297708 JAOD d330 3 90E9 1 OZ N YNnB 9NIB D NS 5591 22 1 3 d0SL 9 411 NOINId LHS 1 04 NS S8p1 12 1 800 0 8150 LE OyaH SI p E IU 1 E NUILYNSN3O BEV 02 00 66 029 ATBNaSSY ONTA 1 YW MUA 80 02 029 III ATBRESSY 35 2 TDS 1 AJEWGSSY 0 010 62 029 11 TUN CA S51 SW CENIHIYN 8nH jnalnn 3va 652 029 906279 12 NIOSH HIND 1 IndIntvaovs 1 600 00 2 27 9 SNINVGH ISTRHL JON 9182 1 US S I H S 8 5 X 01 1 200 10 0 0 INDO 97 1 X VIO 2 1 1 ATENGSSY 30 3 7708 1 8 0 20 5121 SNINV3H TDA ADD 580 E1 8008 1 1 Y v10 ST 029 ET 1SMHL 1 SH HIND 8 39 NIY 910 27 029 wu ATBHBSSY NOLLDH LSTSHL mm 8 JA gru 6 1 810 20 0 SI 72 018 ARIS 135 1 SNINIVI3B 200 022 ov WIHS gt lt 2 YNNA WHE XWWZS WAS TWO 0 0 65 029 6I CEHILON 1 51821 YNI 938 15 9 1 460 00 6421 8 ONINIVI3H 1 gonogo 9NINV38 5 0 100 95 029 2 1 11 BIVA 2 CAND JEAXNGdD DNB E2 8000 0 0 29 1D 1708 d gl 97 1 X YIO 2 1 4 n 2 10 029 OE B1 ZI 55 HITD
8. 129 012HN138 012HM129 026HS104 012CH319 No Req d 1 1 1 c 1 1 1 3 1 1 6 8 4 2 2 1 1 2 8 2 1 8 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Description Housing Axle w Idler Shaft Housing Axle Finished Kit Detent Seal Oil Assembly Actuator Assembly Shift Rod Seal Oil Assembly Tube Assembly Tube Screw Flange Head Screw Socket Head Ring Retaining Bearing Ball Pin Cotter Assembly Brake Assembly Brake Seat Spring Nut Lock Nut Hex Flange Shaft Axle Bolt Wheel Drum Brake Assembly Hub Wheel Screw Flange Head Screw Flange Head Nut Lock Plug Rubber Vent Pin Dowel Bearing Ball Shaft Input Kit Shim Bearing Ball Bearing Ball Spacer Flat Washer Thrust Washer Thrust Gear Assembly Forward Gear Clutch Shaft Intermediate Gear Assembly Reverse Gear Helical Pinion Gear Assembly Idler Ring Retaining Bearing Ball Gear Helical Ring Assembly Differential Nut Lock Bolt Hex Gear Clutch Diff Lock Housing Diff Lock Seal Oil Key No DANA Part No 59 Pa as NP SPICER OUTDOOR POWER EOUIPMENT COMPONENTS DIVISION DANA CORPORATION FREDERICKTOWN OH 43019 SERVICE PARTS REPLACEMENT LISTING DATE ISSUED 01 25 2005 MODEL NO 012AJ399 1 DESCRIPTION AXLE ASSEMBLY REAR FNR w Differential Lock w Output Shaft These Ball Bearings are available packaged together as k
9. 4 WHEEL DRIVE SANAT IN hilinrd TRANSAXLE PARTS BREAKDOWN Gen III Front Drive System Differential Gearcase P N 6203 01 256 Parts and Service Manual Rev 0 Released 11 12 2007 S hilinrd Basic Operation The Hilliard Front Drive System Differential is an electro mechanically activated bi directional overrunning clutch When 12 volts of power is sent to the 4WD switch the unit is activated to engage both front wheels instantaneously whenever the rear wheels loose traction The clutch also releases or overruns automatically the instant the rear wheels regain traction Because torque is transmitted to both front wheels it is a true 4WD The over running characteristics of this system allow for an on demand 4WD engagement and steering ease Specifications Gide en Ne 3 82 1 Input Output Fluid Capacity nana ikan 150ml 5 oz Hilliard CFD Gearcase Lube Voltage cionis Oves Dese angan 12 volts 15 volts max 11 volts min Coil Resistance 2 ect 24 7 ohms to 27 3 ohms at 20 C 68 F Input amp Output Cover Bolt 17 ft Ibs Mounting Bolt TOQUE 32 ft lbs Oil Plug ioter ee 10 ft Ibs Oil Drain Plug Torque 10 ft Ibs External Input Shaft 22 Tooth 24 4
10. 8 Pitch Fillet Root Side Fit Special Class 7 Internal Output Shaft 5 22 Tooth 24 48 Pitch Fillet Root Side Fit Special Class 7 Mounting Feet Thread 5 2 3 8 16 UNC 2B 4 Places x 85 Deep Continuous Torque 145 ft Ibs Input Hilliard CFD Gearcase Oil Part 0756 01 015 T General Maintenance It is recommended that the oil be changed once every 2000 miles To change the oil follow each step on the procedure listed below Oil Change Procedure 1 Remove the oil drain plug located on the bottom of the gearcase using a 5 16 hex key wrench 2 Let all the oil drain out of the unit Catch and discard the oil properly 3 sure to clean off any debris on the drain plug and reinstall Torque the oil drain plug to 10 ft Ibs 4 Remove the oil fill plug using a 5 16 hex key wrench 5 Add 150 ml 5 oz of the Hilliard CFD Gearcase Lube note do not use any other type of oil in this system or the 4WD will not operate properly Reassemble the oil fill plug into the gearcase and torque to 10 ft lbs m Backlash Adjustment 1 Using a 5 32 Allen wrench turn the 10 24 socket head cap screw located inside the hollowed out round boss protruding from the output cover clockwise until it will not move any more do not apply a lot of torque At thi
11. art 40 Pick up the armature plate and wipe off any dirt or sludge Inspect the surface that rides on the coil located in the large output cover There should be a consistent wear mark from the coil Any interruptions in this wear pattern could indicate an out of flatness condition and the armature plate will need to be replaced part 19 You can also check the flatness by setting the armature plate tangs facing up on flat surface or granite block and making sure the plate does not rock If the armature plate wear is consistent and the plate is flat continue on to step 2 2 Clean and inspect the internal clutch components Slowly remove the roll cage part 39 from the clutch housing ring gear part 12 Using a clean dry lint free cloth clean the 14 clutch rollers part 38 the 2 race output hubs parts 16 amp 17 and the internal profile in the clutch housing ring gear part 12 If there are any excessive scratches nicks or deep flats present on any of these parts replace with the proper service kit listed at the bottom of this page 3 With the roll cage out of the Clutch Housing Ring Gear 12 inspect the 14 H Clip Springs part 30 and make sure all the springs are intact and none are broken If any of the springs are broken replace the roll cage assembly with the proper service kit listed at the bottom of this page Problem Gear set is too loud 1 Refer to the Backlash Adjustment section located on the
12. it Order Dana number 012KD124 for this kit The Internal Gears are available packaged together as a kit Order Dana number 012KG106 for this kit Use Shim s as required to maintain proper clearances Sealant is to be applied between Left Hand and Right Hand Axle Housings Sealant is to be applied between Right Hand Axle Housing and Diff Lock Housing Use Loctite Gasket Eliminator No 518 or equivalent 0125 117 314004 4150221 4150223 012HD142 01258171 1 012HM137 5803 012HH140 026HP100 012HG145 No Req d 1 1 1 1 1 1 6 1 1 2 1 Description Assembly Shift Shaft Lever Actuating Screw Hex Head Nut Lock Bearing Ball Shaft Axle Screw Flange Head Switch Seal Oil Bushing Dowel Drain Plug lO ran 2 A LA S Ol rT Q 341 D c l 662PnVvclO ISCOW NOISIAIG SLNHNOdWOD LNANJINOGH WHMOd YOOGLNO 5 NOILVHOdHOO VNVG X8 zc
13. m step 78 onto the large cover plate being sure to line up and insert the tangs from the armature plate 19 into the mating slots on the roll cage part 39 It is very important to make sure the tangs on the armature plate are properly aligned into the slots on the roll cage or you will damage the armature plate and the 4WD will not work Press the race output hub with the 4 bushing part 16 into the gearcase part 28 Insert the gearcase part 728 back onto the large cover plate assembly Be sure the boltholes are lined up and the pinion gear part 36 and the clutch housing ring gear part 712 mesh properly Torque the 7 5 16 18 UNC 2A x 1 long hex head bolts part 2 to 17 425158 Be sure to clean off any dirt or debris on the drain plug part 32 Using a 5 16 hex key wrench reassemble the plug into the bottom of the gearcase torque to 10 ft Ibs Remove the oil fill plug part 37 and fill the unit with 150 ml 5 oz of the Hilliard 4WD CFD Gearcase oil Follow the Backlash Adjustment procedure located on the bottom of page 2 and set the backlash Clutch Repair Kits Available for Standard Clutch Repair RGM Ki oerte east ioa e P N 6203 29 010 0 Race Output Hub P N 6203 27 017 B Clutch Housing Ring Gear Machined P N 6203 13 259 Clutch Assembly de rre eden P N 6203 01 218 Roll Cage Assembly A ong P N 6203 20 098
14. s point you should not be able to turn the pinion gear part 36 Do not tighten the screw 2 Now slowly turn the backlash cap screw counter clockwise while turning the pinion gear at the same time Keep slowly turning the backlash cap screw until the pinion gear can rotate 4 times 1 revolution of the ring gear freely without any tight spots You should only have to turn the backlash cap screw between and of a turn to have the proper backlash set Troubleshooting Problem 4WD will not engage 1 Check the minimum battery voltage going to the CFD Gearcase The voltage should not read below 11 volts for the unit to operate properly If the voltage is at or above 11 volts continue on to step 2 Check the resistance of the coil harness on the large output cover This can be achieved by attaching a multi meter to the 2 terminal pins part 23 on the exploded view drawing located on page 5 The resistance should be 24 7 to 27 3 ohms at 20 C 68 F If the unit does not read any resistance then there is a short in the coil amp wire harness The large Output Cover Sub Assembly P N 6203 12 100 needs to be replaced If the resistance in the coil is satisfactory continue on to step 3 Check the armature plate part 19 for a consistent wear pattern To do this completely drain the oil from the unit by removing the drain plug part 32 located on the bottom of the gearcase with a 5 16 hex key wrench Collect the oil and di
15. spose properly Remove the 7 hex head bolts part 2 from the large cover using a 4 socket Set the unit on a flat surface with the large output cover part 27 facing up Carefully lift the large cover straight up off of the gearcase Remove the clutch housing ring gear part 12 out of the gearcase be sure to hold the roll cage with the clutch housing ring gear to prevent the cage from falling out Remove the retaining ring part 8 out of the large cover and then remove the nylatron plastic shim part 40 Pick up the armature plate and wipe off any dirt or sludge Inspect the surface that rides on the coil part 26 located in the large output cover There should be a consistent wear mark from the coil Any interruptions in this wear pattern could indicate an out of flatness condition and the armature plate will need to be replaced part 11 You can also check the flatness by setting the armature plate tangs facing up on a flat surface or granite block and making sure the plate does not rock If the armature plate wear is consistent and the plate is flat continue on to step 4 Check for the proper coil depth The electro magnetic coil part 26 should set below the pole faces of the metal insert steel u shape piece pressed into the large cover assembly located in the large output cover part 27 To check this simply run your fingers around the pole faces and make sure that the coil is correctly set below the metal insert along the
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