Service Manual
Contents
1. ff M M 09 SCREW MIO 05 MS 08 SCREW M8 05 IS Ped MS 06 TUBE HANDLE MS 05 STUD 02 MS 04 EN V S E 05 BUMPER IS 02 DRIVER 15 01 BASE MAIN Q 3 NO FN QC f D IN TV hAA sp DESCRIPTION Y ATL REMARK E DJ U L ANDLE o 46 30 E 120 87 49 46 er m Pe a Sr 1 10 Ar d Ag 8 SCREW M8X35 9 SCREW M10 TN 4 ar u 3 S 5 Sa ue LI E UD 3 BUM 6 QO i aq 30 96 f 20030 M T n 5 60 El 1362. ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 32
3. ASM 0124 S20BZ122 1 Axle Service Manual DanaHoldingCorporation 28 Steering Cvlinder Taper Removal Tool Steering Cvlinder Taper Removal Tool 29 2 54 0 625 18 UNF 2A THD 43 16 ET 00062090 00000000000000 LESS 10 TIE ROD amp CYLINDER REMOVING TOOL MATL EN8 Dana Holding Corporation A F 32 ASM 0124 S20BZ122 1 Axle Service Manual Tie Rod End Taper Removal Tool Tie Rod End Taper Removal Tool jie I CN 01LZ L 1 C3 ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 30 Final Drive Bracket Tool Final Drive Bracket Tool 01 LOCATER MATL EN 8 TOUGHENED QTY 3NOS DRIVE SHAFT TTR CHECKING PLATE WO 074 10 78 43 110 92 uf PLATE at MATL MS QTY 1NO DRIVE SHAFT TTR CHECKING PLATE WO 074 10 __ VBS 3NUS SCREWED WITH M8 ALLEN SCREW 31 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Welch Plug Driver Tool Welch Plug Driver Tool
4. lt pana gt SPICER Off Highway Products service Manual Axle 920BZ122 1 ASM 0124 March 2014 CONTENTS ASM 0124 S20BZ122 1 Axle Service Manual Maintenance amp Lubrication 1 Data Platt inne 1 Definition of VIEWPOINTS sss 1 Maintenance Intervals 2 Safety Prec utions nes 3 DISASSEMBLY amp REASSEMBLY 4 Exploded VIEW inne 4 Driveshaft amp Hydraulic Line Removal 5 Axie Removal ia 5 Steering Cylinder Removal 5 Tie Rod Removal sense 6 Drain Plug Removal 6 Final Drive Cover Disassembly 6 Final Drive Cover Installation 8 Drop Shaft Disassembly 9 Drop Shaft Assembly amp Installation 10 Knuckle Housing Removal 11 Knuckle Housing Installation 12 Face Seal Installation 14 Shoulder Housing Removal amp Disassembly 15 Shoulder Housing Assembly 16 Carrier Removal 8 Disassembly 18 Carrier Assembly amp Installation 19 Wheel End Installation 22 Tie ROG Installation nr 22 Steering Cyli
5. added to the N other to keep bearing preload from changing 2 Tighten the old pinion nut to 190 210 Ibs ft 8 If bearings R were removed place original shims S 257 285 Nem or new shims equaling the same thickness on the 3 Checkthe rotation of the pinion same side of the differential assembly T from which a Verify the pinion rotation torque is 10 15 Ibs in they were removed 1 13 1 69 Nem a The bearing shim s S control the ring and b If the pinion does not turn within specification pinion backlash and the preload of the adjust the shim pack Add shims if rotation differential bearings If the original differential torque is too high remove shims if rotation case bearings and gear set are being used torque is too low install the original shims or new shims totalling 4 When the pinion is shimmed correctly replace the old the original thickness pinion nut with a new pinion nut b If the differential case bearings or gear set are 2 being replaced set the bearing preload 285 Nem and recheck the rotation of the pinion between the ring gear side bearing and differential case c Shim the bearings until preload is 0 001 0 004 in 0 03 0 09 mm 9 Install new bearings on the differential assembly 10 Using marks made during disassembly install the bearing caps U in their original positions 11 Tighten the capscrews for the bearing caps to 40 50 lbs ft 54 68 Nem 12 Install the differ
6. span ner nut in slot Loosen the spanner locknut using the Final Drive Spanner Nut Socket page 28 11 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Knuckle Housing Installation Knuckle Housing Installation FIGURE 32 6 Remove face seal face seal cup and bearing cone Press off bearing cups from knuckle if necessary Clean and inspect all parts replacing any damaged components FIGURE 33 7 Install bearing cups E amp G into knuckle using appro priate drivers FIGURE 34 8 Install bearing cone D into knuckle housing 9 Install face seal cup C using the Face Seal Cup Driver page 27 The face seal cup C should always be replaced Do not reuse ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 12 Knuckle Housing Installation FIGURE 35 10 Install face seal C using the Face Seal Tool page 25 See Face Seal Installation on page 14 FIGURE 36 11 Lubricate knuckle housing FIGURE 37 12 Install knuckle housing on shoulder assembly 13 Lubricate and install bearing cone H 13 Dana Holding Corporation 14 Install star lockwasher I Add Loctite 277 to spanner nut J threads and install using Final Drive Spanner Nut Socket page 28 and torque to 66 74 lbs ft 90 100 Nem 15 Rock knuckle housing F back and forth to seat bearing rollers and re torque spanner nut to 66 74 Ibs ft 90 100 Nem Repeat
7. to the relative law provisions obtaining in the country where the axles are being overhauled Make sure that only weak solvents are used for cleaning purposes avoid using turpentine dilutants and toluol xylol based or similar solvents use light solvents such as Kerosene mineral spirits or water based environment friendly solvents For the sake of clarity the parts that do not normally need to be removed have not been reproduced in some of the diagrams For agricultural axles the terms RIGHT and LEFT refer to the position from the operator s seat For construction axles the terms RIGHT and LEFT refer to the position outside facing the machine with the input drive facing forward After repair work has been completed accurately touch up any coated part that may have been damaged Follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Indicates an imminently hazardous situation which if not avoided will result in death or DANGER serious injury Indicates an imminently hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury Indicates a situation which if not avoided may result in if not avoided may result in damage to NOTICE components Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual DISASSEMBLV amp REASSEM
8. 1 Dana Holding Corporation Locate the or number C on the end of the pin 6 Theshim pack thickness to be used under the pinion bearing cup is calculated as follows a Use the feeler gauge thickness dimension measured in previous distance measuring step b If the number on the pinion is a number SUBTRAGT that number in thousandths of an inch from the feeler gauge thickness dimension measured in previous distance measuring step c If the number on the pinion is a number ADD that number in thousandths of an inch to the feeler gauge thickness dimension measured in previous distance measuring step d After calculating shim pack thickness assemble a shim pack measuring the exact amount calculated above and place it under the pinion bearing cup Differential Bearing Preload FIGURE 61 1 Place the bearing substitute tool D on each side of the differential case 2 Prythe differential back and forth with a small bar to seat the bearing tools against the outer edges of bearing bores 3 Prythe differential all the way over against one of the bearing tools 4 Using a feeler gauge measure the gap between the differential carrier and the bearing tool E Record the measurement 5 Add 0 001 0 004 in 0 03 0 09 mm to the measure ment for bearing preload 6 Assemble a shim pack measuring the exact amount as the calculation above ASM 0124 S20BZ122 1 Axle Service Manual Wheel E
9. 46 FIGURE 43 5 Remove bearing and lower shoulder 15T gear assembiv from shoulder housing 2 Remove four capscrews fastening shoulder housing to axle housing JA FIGURE 44 3 Remove the internal snap ring and any shim s from Q shoulder housing FIGURE 47 6 If necessary press off gear from bearings Clean and inspect all parts replacing any damaged compo nents FIGURE 45 4 Remove bearing and upper shoulder 12T gear assembly from shoulder housing NOTE The bearings are pressed onto the gears and the assem blies are slip fit into the housing 15 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Shoulder Housing Assembly Shoulder Housing Assembly FIGURE 51 FIGURE 48 3 Install internal snap ring to shoulder housing NOTE Do not install shims B until backlash measurements are taken FIGURE 49 1 Install bearing and lower shoulder 15T gear assembly into shoulder housing FIGURE 52 4 Measure end play of the upper shoulder gear To set the end play a Measure distance between the bearing and the snap ring at several locations b Assemble shims such that end play is within 0 006 0 011 in 0 15 0 28 mm This will ensure backlash is 0 004 0 008 in 0 10 0 20 mm FIGURE 50 2 Install bearing and upper shoulder 12T gear assem bly into shoulder housing ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 16 Shoulder
10. BLY Exploded View ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 4 Driveshaft amp Hvdraulic Line Removal Driveshaft amp Hvdraulic Line Removal Steering Cvlinder Removal Disconnect the steering cvlinder hvdraulic lines 2 Remove the spring pin from the driveshaft splined connector 3 Support the driveshaft and slide the splined connec tor toward the center of the driveshaft to remove the driveshaft from the machine Axle Removal FIGURE 3 1 Remove cotter pins castle nuts and washers FIGURE 1 1 Remove axle completely supporting the axle with a hoist and remove front wheels Place the axle on workbench or blocks to disassemble Tool FIGURE 4 2 Remove steer cylinder NOTE Oylinder ball end studs are tapered Use a Steering Cylinder Taper Removal Tool page 29 to avoid damaging threads if cylinder is to be reused FIGURE 2 2 Remove front and rear trunnions Inspect axle pin bushings and replace if required NOTE When removing the rear trunnions also remove the inverted v ring thrust washer and the v ring on the housing When removing the front trunnion also remove the v ring and thrust washer 5 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Tie Rod Removal Tie Rod Removal FIGURE 5 1 Remove the cotter pin and the castle nut from tie rods FIGURE 6 2 Usinga tie rod end removal tool r
11. GURE 67 2 23 Install thrust washer B on rear trunnion A It might be necessary to apply grease to thrust washer to hold it in place Install v ring seal C on carrier pin D Slide rear trunnion A on carrier pin D Grease the rear trunnion grease zerk until grease purges from the v ring Dana Holding Corporation FIGURE 68 6 Install thrust washer C on front trunnion D It might be necessary to apply grease to thrust washer to hold it in place Install v ring seal B on axle pin A Slide front trunnion D on axle pin A Grease the front trunnion grease zerk until grease purges from the v ring Axle Installation amp End Play Adjustment Install axle into vehicle Install front trunnion hex nut E loosely on bolt F Thread bolt F into front trunnion D and tighten to 24 Ibs ft 82 Nem Tighten back the hex nut E until tight against front trunnion D ASM 0124 S20BZ122 1 Axle Service Manual Toe in Adjustment Toe in Adjustment FIGURE 69 NOTE This procedure is for toe in adjustment off the vehicle The toe in adjustment must be performed again on the vehicle 1 Jackup front axle so tires are off floor 2 Rotate tire by hand and scribe a line near the center of each of the front tires NOTE One of the tie rod ends and jam nut has left hand threads 3 Measure and record the distance between the lines at the front and the rear of the tire a
12. Housing Assembly FIGURE 53 5 Apply Loctite 515 to mating surfaces of the axle and shoulder housing NOTE Bolts used to fasten shoulder housing to axle housing are special bolts and should be replaced after disassembly Washers used to fasten shoulder housing to axle housing are special hardened washers 6 Apply Loctite 262 to the threads and install cap screws fastening the shoulder housing to the axle housing Tighten the four capscrews to 210 2 231 5 lbs ft 285 314 Nem 17 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Carrier Removal amp Disassembly Carrier Removal amp Disassembly FIGURE 54 1 Drain oil from front axle housing and both final drives 2 Before removing the carrier remove the driveshaft see page 4 axle see page 5 steering cylinder see page 5 tie rods see page 6 right hand and left hand wheel end assemblies and axle shafts 3 Remove capscrews fastening the carrier housing to the axle housing and remove carrier assembly 4 Mark bearing caps and carrier housing to assure they are assembled in their original positions 5 Remove capscrews from the bearing caps 6 Remove differential assembly from carrier housing NOTE The differential assembly and internal parts come as an assembly If any damage is apparent there is no need to disassemble the case as the whole assembly must be replaced Remove ring gear capscrews 8 Remov
13. ce Manual FIGURE 17 c Assemble the shim retainer plate and USED spindle nut to output shaft and tighten the nut to 330 360 Ibs ft 447 2 488 Nem d Using the Final Drive Bracket Tool page 31 verify the rolling torque of the final drive cover is 54 76 Ibs in 6 1 8 6 Nem e If the rolling torque is not correct reselect shims C to achieve the correct rolling torque f If the rolling torque is correct remove the USED spindle nut Using a NEW spindle nut B apply Loctite 272 to the threads and tighten nut to 330 360 Ibs ft 447 2 488 Nem iua FIGURE 18 9 Install final drive cover to knuckle housing tightening capscrews to 22 28 lbs ft 30 38 Nem Dana Holding Corporation 8 Drop Shaft Disassembly Drop Shaft Disassembly FIGURE 19 i FIGURE 22 4 Remove bevel pinion from drop shaft 1 Carefully remove welch plug from knuckle housing ri M _ FIGURE 20 DM FIGURE 23 5 Remove snap ring from knuckle housing 2 Remove snap ring from drop shaft n EE e FIGURE 21 3 Remove washer and shim s from drop shaft Save all FIGURE 24 shim s between the washer and bevel gear 6 Remove drop shaft and bearing from knuckle hous ing 9 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Drop Shaft Assembly amp Installation Drop Shaft Assembly amp Installation e FIGURE 25 7 Remo
14. d output shaft o o FIGURE 15 8 Clean and inspect all parts replacing any damaged components ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation Final Drive Cover Installation Final Drive Cover Installation A Spindle Nut B Retainer Plate C Shim D Bevel Gear E Bearing Cone F Bearing Cup G O ring H Final Drive Cover Bearing Cup J Bearing Cone K Face Seal L Output Shaft 1 Install bearing cups F amp I to the final drive cover H 2 Install the bearing cone J to the output shaft L FIGURE 16 3 Using the Face Seal Tool page 25 install the face seal K on the final drive cover H and output shaft L See Face Seal Installation on page 14 for cleaning of face seal 4 Install the final drive cover H to the output shaft L 5 Install the bearing cone E to the bevel gear D 6 Install the bevel gear D to the final drive cover and output shaft assembly H amp L Install new o ring G on final drive cover H 8 To adjust bearings a To ensure proper seating of the bearing roll and oscillate the 41T gear D b To select shims C start with old shim and install additional shims as required on the output shaft NOTE For initial assembly and measurements assemble final drive with the USED spindle nut Do not use a NEW spindle nut until final assembly as this nut is torque prevailing ASM 0124 S20BZ122 1 Axle Servi
15. e rubber o ring on the seal ring ensure that it is uniformly seated on the retaining lip and is not twisted EN 7 FIGURE 39 FIGURE 40 4 Place the seal in the Face Seal Tool page 25 and locate this assembly squarely against the top of the conical seal ASM 0124 S20BZ122 1 Axle Service Manual FIGURE 41 5 Spray the o ring and seat with isopropyl alcohol to act as a lubricant to the o ring FIGURE 42 6 Use sudden and even pressure to push in the seal and ensure the retaining lip is not twisted or pinched 7 The sealing ring face should be parallel to the conical seal face within 0 50 mm see Figure 39 8 After installing the seal halves wipe both metal seal ing faces clean with a lint free cloth NOTE Metal face seals should be replaced when the distance between the seal inner diameter and seal contact band is less than 5096 of the distance between the seal inner diam eter and the outer diameter 9 Then apply a coat of clean MSs oil to the metal seal faces with a lint free applicator The oil must not wet surfaces other than the sealing faces 10 Clean the metal surfaces with lint free cloth 1 MSS8 oil is mineral based oil ranging from 10W to 90W Dana Holding Corporation 14 Shoulder Housing Removal amp Disassembly Shoulder Housing Removal amp Disassembly 1 Remove knuckle housing See Knuckle Housing Removal on page 11 FIGURE
16. e the ring gear from the differential case 9 Clean and inspect all parts and check parts for wear 10 Replace any unserviceable parts ASM 0124 S20BZ122 1 Axle Service Manual A Pinion B Bearing Cone C Bearing Cup D Inner Pinion Shim E Carrier Housing F Pinion Bearing Spacer G Pinion Bearing Preload Shim H Bearing Cup l Bearing Cone J O ring K Spacer L Oil Seal M Slinger N Pinion Nut 11 Remove pinion nut Do not discard nut at this time The pinion nut is a special nylock nut Always replace this nut Do not reuse Never tighten a nylock nut with an impact wrench Always use a torque wrench to correctly tighten nylock nuts 12 Remove pinion from carrier housing NOTE The ring gear and pinion gear are serviced as an assembly If either the ring gear or pinion has wear or damage both must be replaced 13 Disassemble pinion shaft assembly 14 Clean and inspect all parts and check parts for wear 15 Replace any unserviceable parts Dana Holding Corporation 18 Carrier Assembly amp Installation Carrier Assembly amp Installation A Pinion B Bearing Cone C Bearing Cup D Inner Pinion Shim E Carrier Housing F Pinion Bearing Spacer G Pinion Bearing Preload Shim H Bearing Cup l Bearing Cone J O ring K Spacer L Oil Seal M Slinger N Pinion Nut FIGURE 55 b If ring and pinion are being replaced notice the 1 Assemble bearing cone B to
17. emove tie rod ends from knuckles NOTE Tie rod ball end studs are tapered Use a Tie Rod End Taper Removal Tool page 30 to avoid damaging threads if tie rod is to be reused NOTE One of the tie rod ends and jam nut has left hand threads Drain Plug Removal FIGURE 7 1 Remove plugs and drain oil from final drive housings and main axle Final Drive Co n ver Disassembly M FIGURE 8 1 Remove capscrews from final drive cover 0 FIGURE 9 2 Separate final drive cover and output shaft from final drive housing NOTE It may be necessary to pry the cover from the housing using the two pry bars on each side of the cover FIGURE 10 3 Loosen output shaft nut and remove nut plate retainer and shim NCAUTION The retaining nut on the output shaft is a special torque prevailing nut Always replace this nut Do not reuse Never tighten a torque prevailing nut with an impact wrench Always use a torque wrench to correctly tighten torque pre vailing nuts ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 6 Final Drive Cover Disassembly FIGURE 11 4 Remove 41T bevel gear from output cover l A af E s l f II fi f 7 iz Se M FIGURE 12 5 Remove the output cover FIGURE 13 6 Remove face seal from the output cover and the out put shaft FIGURE 14 7 f necessary press bearings off of bevel gear an
18. ential case assembly to the carrier housing 13 Check gear backlash with a dial indicator to 0 004 0 008 in 0 10 0 20 mm FIGURE 58 14 S d IMMA housing and carrier has 6 Install the ring gear to the differential case Abort id NEE EEE hou 7 Tighten the ring gear bolts to 58 65 Ibs ft 79 88 Ae dd a wl ad 95 nii Nem 16 Install the carrier housing to the axle housing 17 Apply Loctite 262 to all capscrews securing the car rier housing 18 Tighten the capscrews to 74 4 79 6 Ibs ft 101 108 Nem ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 20 Carrier Assembly amp Installation Pinion Depth Setup amp Adjustment NOTE This procedure is required only if a new gear set is being installed A FIGURE 60 Tools Required e JDG 1395A Differential Setup Tool Kit 1 Remove inner pinion bearing cup if installed and retain any shims for possible reuse 2 Install tool A into pinion bearing bore 3 Install tool B across differential bearing saddles 4 While holding the tool B down measure the dis tance between the two tools with a feeler gauge This value will generally be between 0 026 0 034 in 0 64 0 86 mm but it is acceptable to have mea surements between 0 018 0 038 in 0 45 0 96 mm Hecord the measurement ion gear This number indicates the best running position of each particular gear set in thousandths of an inch 2
19. ing are special hardened washers 3 Apply Loctite 262 to the threads and install cap screws fastening the shoulder housing to the axle housing Tighten the capscrews to 210 2 231 5 Ibs ft 285 314 Nem Tie Rod Installation FIGURE 64 1 Inspect tie rod end boots replacing boots as needed 2 Insert tie rod ends into holes in knuckle arms 3 Install two castle nuts to tie rod ends 4 Tighten castle nuts A to 99 5 110 6 Ibs ft 135 150 Nem NOTE Only grease tie rods if grease zerk is present 5 Install cotter pins If slots in castle nuts do not align with holes after torquing tighten nuts until next slot aligns 6 Lubricate tie rod ends using general purpose grease 7 Adjust toe in See Toe in Adjustment on page 24 8 Install wheel and tire to final drive Dana Holding Corporation 22 Steering Cvlinder Installation Assemble Front Trunnion Steering Cvlinder Installation FIGURE 66 1 Inspect rubber boots on ends of cvlinders Replace boots if necessarv Install cvlinder and tighten castle nuts to 84 8 94 4 Ibs ft 115 128 Nem If slots in castle nut do not line up with cotter pin hole continue tightening nut until next slot lines up Axle Trunnion Installation 1 Raise front axle off ground to take weight off the front axle NOTE Ensure the inverted v seal is installed inside the rear trun nion bore A before proceeding Assemble Rear Trunnion FI
20. nd Installation Differential Backlash Adjustment NOTE Pinion shaft assembly must be installed FIGURE 62 1 Install pinion shaft See Carrier Assembly amp Installa tion on page 19 2 Divide the shim pack and a bearing substitute tool on each side of the differential case 3 Install dial indicator to measure ring gear movement Hold the pinion gear shaft to keep it from moving 5 Rotate the ring gear back and forth and observe readout on dial indicator is to specification of 0 004 0 008 in 0 10 0 20 mm Whatever shim thickness is added to one side of the dif ferential case must be removed from the other side Or whatever shims are removed from one side must be added to the other to keep bearing preload from chang ing a If necessary adjust backlash Gear backlash is adjusted by changing the shim pack thickness on the ring gear side bearing Removing shims increases backlash adding shims decreases backlash b When backlash is correct removing bearing substitute tools and install bearings 6 Install the bearing caps 7 Tighten the capscrews for the bearing caps to 40 50 lbs ft 54 2 67 8 Nem and recheck backlash ASM 0124 S20BZ122 1 Axle Service Manual Wheel End Installation FIGURE 63 1 Ensure old Loctite on axle housing and shoulder has been removed properly 2 Apply Loctite 515 to the shoulder housing NOTE Washers used to fasten shoulder housing to axle hous
21. nder Installation 23 Axle Trunnion Installation 23 Toe in Adjusiment una 24 Driveshaft amp Hydraulic Line Installation 24 ope ial TOONS e 25 Seal Tool iii ie e gibed 25 Face Seal Cup Driver 27 Final Drive Spanner Nut Socket 28 Steering Cylinder Taper Removal Tool 29 Tie Rod End Taper Removal Tool 30 Final Drive Bracket Tool 31 Welch Plug Driver Tool 32 Dana Holding Corporation MAINTENANCE amp LUBRICATION Data Plate Model Number Build Date DDMMVV Serial Number Definition of Viewpoints LEFT SIDE m TI RIGHT SIDE DIRECTION 1 Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Maintenance Intervals Maintenance Points Front Trunnion LA Le DA KI N egr aA SL GA Wa en IZ ae Smm EO 427 ee DR ILL RAEN ofr IN f Y 1 Oil fill plug 2 Oil drain plug 3 Check level plug 4 Grease zerk 5 Front trunnion thrust bolt Maintenance Intervals Frequenc Oil Check Levels Every 50 hours check level on dipstick J20C Oil Change Initially after 100 working hours Every 600 hours Greasing Front amp Rear Trunnion Dry land a
22. pinion A or number P on end of pinion gear This l indicates the best running position of each a Place inner shim s D under bearing cup C to particular gear set in thousandths of an inch If set pinion height If the original pinion is being the number on the new set is not the same as used use the original shims or install new shims the number on the one being replaced adjust the same thickness as original shims the height by adding or removing inner shim s B from original shim pack according to dimension etched in head of pinion Example If the old pinion reads 42 and the new pinion is marked 1 add 0 003 in shims to the original pack FIGURE 56 19 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Carrier Assembly amp Installation FIGURE 57 NOTE Number Q on pinion and ring gear indicate matched set Make sure numbers on ring and pinion gears match before assembling FIGURE 59 c Assemble the inner bearing cup C and anv shims D in the carrier housing E d Install the pinion A in the carrier housing E There mav be several shims on each differential case and install the spacer F outer shim G Whatever shim thickness is added to one side of the differ bearing cup H bearing cone l o ring J ential case must be removed from the other side Or what spacer K oil seal L slinger M and pinion nut ever shims are removed from one side must be
23. pplications Weekly or every 50 hours whichever is earlier NLGI 3EP Wet land applications Daily Tightening Front Trunnion Bolt Every 600 hours verify Thrust bolt torque 11 22 Ibs ft 15 30 Nem Jam nut 129 147 Ibs ft 175 200 Nem Wheel Nuts Initially after 10 working hours Every 200 hours ASM 0124 S20BZ122 1 Axle Service Manual DanaHoldingCorporation 2 Safetv Precautions Safetv Precautions 1 N o T eo 3 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 When removing one of the arms an anti tilting safety trestle should be placed under the other arm When working on an arm that is fitted on the machine make sure that the supporting trestles are correctly positioned and that the machine is locked lengthways Do not admit any other person inside the work area mark off the area hang warning signs and remove the ignition key from the machine Use only clean quality tools discard all worn damaged low quality or improvised wrenches and tools Ensure that all dvnamometric wrenches have been checked and calibrated Always wear gloves and non slip rubber shoes when performing repair work Should you stain a surface with oil remove marks straight away Dispose of all lubricants seals rags and solvents once work has been completed Treat them as special waste and dispose of them according
24. t about axle height The front measurement should be less than the rear measurement 4 If measurement is not correct loosen jam nuts on both ends of tie rod and turn the tie rod B using a wrench to increase or decrease the amount of toe until the measured dimension is 0 0 125 in 0 3 mm 5 Apply Loctite 262 and tighten the jam nuts A to 173 192 Ibs ft 235 260 ASM 0124 S20BZ122 1 Axle Service Manual Driveshaft amp Hydraulic Line Installation FIGURE 70 1 Position driveshaft onto machine While supporting drive shaft slide splined connector toward machine 2 Install spring pin A to drive shaft splined connector 3 Connect steering cylinder hydraulic lines Dana Holding Corporation 24 SPECIAL TOOLS Face Seal Tool Left Hand Side 110 74441 25 Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Face Seal Tool Right Hand Side ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 26 Face Seal Cup Driver Face Seal Cup Driver 100 2109 6 0 1 3 9 20 DOLLY FOR FACE SEAL CUP PRESSING MATL MS 1NO 27 Dana Holding Corporation ASM 0124 S20BZ122 1 Axle Service Manual Final Drive Spanner Nut Socket Final Drive Spanner Nut Socket 01 SOCKET MATL EN 8 IOUCHENED QTY A2NOS PINION NUT TORQUING SHOULDER WO 095 10 3i 5003 63 020 1
25. this step a minimum of 4 times until the nut will no longer advance T i FIGURE 38 16 Fold two tabs of the star lockwasher fully into the spanner nut slots to lock nut into place If tabs are not aligned with spanner nut slots advance nut slightly until two tabs align Ensure tabs are squarely seated into slots The star lockwasher l should always be replaced Do not reuse 17 Install drop shaft See Drop Shaft Assembly amp Installation on page 10 18 Install final drive cover See Final Drive Cover Instal lation on page 8 ASM 0124 S20BZ122 1 Axle Service Manual Face Seal Installation Face Seal Installation The face seal cup should always be replaced Do not reuse Replace damaged seals If metal face seals are dam aged the face seal o rings should also be replaced Clean metal face seal rings with a non petroleum based solvent 1 Housing components that contact the rubber seal must be free from foreign material oil grease dirt metal chips dust or lint particles etc before install ing the seal This should be done using a lint free wipe and a non petroleum based solvent Dry with a clean wipe 2 Clean face seal o ring with isopropyl alcohol spray prior to installation to remove anv debris NOTE Sealing rings must be handled with care Lapped sealing faces must not be damaged scratched or contaminated with dirt or grease 3 When installing th
26. ve the snap ring and bearing from the drop shaft FIGURE 27 1 Install snap ring B and bearing C on drop shaft A 2 Install drop shaft A assembiv in final drive housing I 3 Install internal snap ring D in final drive housing 4 Install bevel pinion E any shim s F washer G and snap ring H on drop shaft Install final drive cover assembly to knuckle housing 6 To set lower final drive backlash shim F the bevel gear end play to 0 025 0 030 in 0 64 0 76 mm FIGURE 26 8 Inspect all drop shaft parts and replace any unser viceable components o g er 4 E A wall FIGURE 28 7 The end play sets backlash to 0 005 0 007 in 0 13 0 18 mm ASM 0124 S20BZ122 1 Axle Service Manual Dana Holding Corporation 10 Knuckle Housing Removal FIGURE 30 4 Remove spanner locknut star lockwasher and bear ing cone FIGURE 29 8 Apply Loctite 380 480 to a new welch plug 1 and install to Knuckle housing using the Welch Plug Driver Tool page 32 The welch plug should always be replaced Do not reuse Knuckle Housing Removal 1 Remove final drive cover See Drain Plug Removal on page 6 2 Remove final drive drop shaft See Drop Shaft Dis assembly on page 9 FIGURE 31 5 Remove knuckle housing from shoulder housing L 4 LETT 3 Straighten tabs on star lockwasher that secure
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