Service Manual
Contents
1. 67 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SPECIAL TOOLS T3 D44H7 68 40 82 2x45 14 68 08 8 06022 0 30 035 040 065 40 0 030 0 060 20H7 n6 265 0 04 0 08 10 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SPECIAL TOOLS T4 mn OOOO Ku ANN AAAA 27 OZ EH 0 PROTECT FROM CARBURIZING 418 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 69 SPECIAL TOOLS T5 390 335 5x45 70 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SPECIAL TOOLS 50 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 71 SPECIAL TOOLS DIN 5480 W32x1 25x24 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SPECIAL TOOLS 260 290 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual2. ZENON ONO 52 BEVEG PINON ia ia 57 Aa 57 BD oasis dam en 58 ASS A 61 ea 67 67 na nan 67 68 Ma 69 PODAC 70 au 71 an 72 Naa 72 CRP A 73 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 3 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual INTRODUCTION The efficiency and continued operation of mechanical units depend on constant correct maintenance and also on efficient repair work should there be a break down or malfunction The instructions contained in this manual have been based on a complete overhaul of the unit However it is up to the mechanic to decide whether or not it is necessary to assemble only individual components when partial repair work is needed The manual provides a quick and sure guide which with the use of photographs and diagrams illustrating the various phases of the ope rations allows accurate work to be performed All the information needed for correct disassembly checks and as sembly of each individual component is set out below In order to remove the differential unit from the vehicle the manuals provided by the vehicle manufacturer should be consulted In describing the following operations it is pre sumed that the unit has already been removed from the vehicle IMPORTANT In order to facilitate work and protect both
3. FIGURE 16 Lubricate the bushing 15 and the seat Install the bushing 15 using tool T3 See drawing T3 p 68 3 o FIGURE 20 Fit the snap ring 11 of the bearing 10 da Er L Carefully check that snap ring 11 is completely inserted FIGURE 17 Lubricate and fit the sealing ring 14 onto tool 4 See drawing T4 p 69 install the rings into the arm AN CAUTION FIGURE 21 Lubricate the outer surface of the sealing ring 12 and assemble it into its position FIGURE 18 Lubricate the top and bottom thrust blocks 5 and fit them into the fulcrum holes of the arm NOTE Verifv at end of stroke ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 27 ASSEMBLY FIGURE 22 Lubricate the terminal of the u joint 13 and in stall in the steering knuckle FIGURE 23 Install the shim 8 and snap ring 9 of the stee ring knuckle FIGURE 24 Tighten fully into the hole provided two double joint lifting eyes size M16 connect to suitable lifting gear and tighten Pay attention not to damage the dust cover rings and the se aling rings Install the steering knuckle 28 Dana Holding Corporation FIGURE 25 Using a drift insert the front seal thrust plate 4 Lubricate the surface of the sealing ring 4 and assemble it into position Carefully check that the rings 4 are properly oriented FIGURE 26 Install the bearing 5 FIGURE 27 Grease gen
4. lt gt SPICER Off Highway Products Service Manual Axle 730 563 ASM 0178E July 2013 CONTENTS INTRODUCTION 5 MAINTENANCE amp LUBRICATION coco momo 6 MAINTENANCE amp LUBRICATION a de A AA 6 DEFINITION OF VIEWPOINTS 5542 555 do a aan 6 DATA BA a 6 CONVERSION TABLES ONSU 7 TORQUE SPECIFICATIONS ne 8 E 8 FIN GE a RAN NN RA 8 WHEEL NUT TIGHTENING TORQUES 9 MAINTENANCE 20 NCW 10 MAINTENANCE INTERVALS gazy Gd a 11 ADJUSTMENT AND CHECKS tac WA ta 11 LUBRICANT 8 SEALANT SPECIFICATIONS sense 12 SAFETY PRECAUTIONS aiw rade ciii na danka ae tonneau dok 13 PLANETARY REDUCTION GEAR sa ik 15 oO GD A Z de ad 15 BIS B aa 16 AGE a 19 STEERING KNUCKIE w dita ui di 23 W O A EE S 23 EPE a AAA 24 ENO 27 STEERING SENSOR a AGE kad A dak 0 33 Aloe naa SA ra aa 33 RO R NA A ce 34 SE AA 36 STEERING CYLINDER aa aa 39 EXPLODED VIEW neien EN 39 DA ENDET d a AO AA a 40 AEP ti a eni 42 DIFFERENTIA C risna 47 P PLODEP WIEN e a 47 DIGA SEM a E 48
5. Anaerobic adhesive for fast and high strength gluing of cylindrical metal joints hub on shaft Can glue together parts with clearance ranging between 0 1 and 0 25 mm LOCTITE 648 Anaerobic adhesive for fast and medium strength gluing of cylindrical metal joints hub on shaft Can glue together parts with radial clearance below 0 1 mm AREXONS REPOSITIONABLE JOINTING COMPOUND FOR SEALS Solvent based sealing compound for elastic seals drying through evaporation Used for sealing the outer diameter of sealing rings for rotating shafts with outer metal reinforcement SILICONE Semi fluid adhesive material used for sealing and filling and to protect components from environmental and phy sical 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 molvbdenum disulphide used to lubricate articulation pins and to prevent sti cking and oxidation of parts that are not lubricated on a regular basis LITHIUM BASED GREASE Applied to bearings sliding parts and used to lubricate seals or parts during assembiv 12 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SAFETY PRECAUTIONS 1 During all operations described in this manual the axle should
6. Install the bearing 5 30 Dana Holding Corporation FIGURE 37 Grease generously the bearing 5 and the thrust block 5 4 104 128 Nm 4 FIGURE 38 Tighten the new capscrews 1 of articulation pins 2 in sequence using the criss cross method Torque wrench setting 104 128 Nm 200 220 N m FIGURE 39 Install the tie rod nuts and lock into position using a torque wrench setting of 200 220 Nm AN CAUTION Check that rubber guards are intact ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 40 Fit the planetary gear cover onto the wheel hub For details see PLANETARY REDUCTION GEAR p 15 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 31 32 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual STEERING SENSOR EXPLODED VIEW 11 0 10 33 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV DISASSEMBLV FIGURE 2 Disconnect the tapered pins of the tie rod from the steering knuckle using a puller FIGURE 6 Remove the drag shaft of the sensor 6 and the 1 rubber joint 5 FIGURE 3 Remove the steering sensor 2 34 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 7 Loosen and remove the capscrews 8 from the kingpin 9 NOTE Screws cannot be re used FIGURE 1
7. 15 Note the position of assembly ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 49 DISASSEMBLV FIGURE 16 Remove the three spider blocking pins 22 bv using a pin driver FIGURE 14 Using a plastic hammer take the half box 16 24 to pieces FIGURE 17 Move the two opposite mounted short bolts 21 to the outside of the box using the same pin driver FIGURE 15 Remove the shim washer 17 and the planetary gear 18 FIGURE 18 Remove the bolts 21 with the help of a drift 50 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 19 Remove the cross bolts 29 FIGURE 22 Connect a suitable lifting svstem Loosen and remove the screws 27 securing the arm to the bodv Remove the arm FIGURE 20 Remove the two half bolts 21 spherical wa shers 19 and satellite wheels 20 FIGURE 23 Bv means of a puller remove the thrust block of the bearing 25 Remove the shims 26 located under the outer thrust block of the bearing 25 FIGURE 21 Remove the shim washer 17 and the planetarv gear 18 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 51 ASSEMBLY ASSEMBLY i a FIGURE 27 Insert the two half bolts 21 spherical washers 19 and satellite gears 20 FIGURE 24 Insert the thrust block 25 and the shims 26 NOTE For the regulation of the pre charge bearings use the ori ginal shims p
8. applying grease install the o ring 4 6 in side the cylinder 54 Dana Holding Corporation FIGURE 39 Fit in position the sleeve 9 complete with ring 7 FIGURE 40 Fit in position the spacer 3 complete with stop rings 2 NOTE make sure the ring is inserted completely FIGURE 41 Lubricate the piston seating Install the piston pack Tap lightly with a mallet to seat the piston 5 completely Mind the position of assembly ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 42 Position the spring 8 Fit the spring guide sleeve 10 on the spring 8 FIGURE 45 Insert the snap ring 11 and slowly loosen the nuts FIGURE 43 Insert an M14 threaded rod in the arm correlated with a swab from the appropriate diameter and a hard stop k 1 r a FIGURE 44 acting the buffer spring guide sleeve 10 tighten the nuts on the threaded rod compressing the spring 8 ASM 0178E 730 563 Axle Service Manual FIGURE 46 Insert a new o ring on the centering diameter of the am Position the arm on the central body Tighten nuts 27 in two stages using the criss cross method Dana Holding Corporation 55 56 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual BEVEL PINION EXPLODED VIEW ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 57 DISASSEMBLV DISASSEMBLV FIGURE 4 Ex
9. sensor 2 in position tightening the screws 1 to 2 5 3 Nm FIGURE 20 Install the snap ring 4 NOTE Make sure that the ring is properly set in its seat ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 37 38 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual STEERING CYLINDER EXPLODED VIEW ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 39 DISASSEMBLV DISASSEMBLV FIGURE 4 Remove the securing screws 4 from the steering cvlinder FIGURE 1 Remove the nuts 1 that lock the tie rods ay ra hy FIGURE 2 Disconnect the tapered pins of the tie rods 2 from the steering knuckle using a puller AN CAUTION z gt L Before attempting to disassemble the unit drain the oil in a _ the cylinder chambers completely FIGURE 3 Disconnect steering bars 3 from the piston FIGURE 6 Remove the snap ring of the cylinder head 40 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 7 Hammer the piston on the rear of the head using FIGURE 10 Remove all seals anti extrusion rings and scra a plastic hammer per rings from head cvlinder and piston Continue hammering until the head is ejected from the cvlin der NOTE seals must be replaced every time the unit is disas sembled Particular attention must be paid not to d
10. working surfaces and operators it is advisable to use pro per equipment such as trestles or supporting benches plastic or copper hammers appropriate levers pullers and specific spanners or wrenches Before going on to disassemble the parts and drain the oil it is best to thoroughiv clean the unit removing any encrusted or accumulated grease INTRODUCTORY REMARKS All the disassembled mechanical units should be thoroughiv 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 CLASSIFICATION This manual classifies units according to part numbers For a correct interpretation classification is indicated as follows bb O up to the part number O BB from part number When no classification is given disassembly and assembly operations are the same for all versions SPECIFIC EQUIPMENT AND SPARE PARTS The d
11. 1 Remove the pin 7 FIGURE 8 Remove the upper kingpin 9 complete with front seal ring and shims FIGURE 9 Loosen and remove the capscrews 10 from the kingpin 11 Remove the bottom kingpin 11 NOTE Screws cannot be re used ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 35 ASSEMBLY 104 128 ASSEMBLY FIGURE 15 Install the kingpin 9 Tighten the new capscrews 8 of top kingpin 9 in sequence using the cross tightening method Torque wrench setting 104 128 Nm FIGURE 13 Tighten fully into the hole provided two double s joint lifting eyes size M16 connect to suitable lifting gear and FIGURE 16 FOR MODELS WITHOUT SENSOR tighten Remove the cap 12 before installing sensor Pay attention not to damage the dust cover rings and the se aling rings Install the steering knuckle 200 220 Nm 104 128 N m FIGURE 17 Insert the kingpins in the steering knuckle and lock into position using a torque wrench setting of 200 220 FIGURE 14 Install the kingpin 11 N m Tighten the new capscrews 10 of bottom articulation pins in sequence using the criss cross method Torque wrench setting 104 128 N m N CAUTION Check that rubber guards are intact 36 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY Loctite 243 2 5 3 FIGURE 22 Apply Loctite 243 to the screws 1 and tighten Fasten the
12. GEAR p 15 NOTE Screws cannot be re used FIGURE 5 Remove the upper kingpin 2 complete with front seal ring 4 and shims 3 FIGURE Disconnect the tapered pins of the tie rod from the steering knuckle using a puller FIGURE 6 Loosen and remove the capscrews 6 from the kingpin 7 Remove the bottom kingpin 7 NOTE Screws cannot be re used 24 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 7 Remove the bearing 5 from the knuckle post 2 FIGURE 10 Remove the u joint 13 T Remove the sealing ring 4 from the knuckle post 2 7 FIGURE 11 Using a puller remove the sealing ring 12 from the steering knuckle FIGURE 12 Remove the snap ring 11 from the steering FIGURE 9 Remove snap ring 8 and the shim 9 from the knuckle steering knuckle ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 25 DISASSEMBLV FIGURE 13 Using a puller remove the bearing 10 from the steering knuckle FIGURE 14 Using an extractor for inner parts remove the top and bottom thrust blocks 5 FIGURE 15 Using an extractor for inner parts remove the seal ring 14 and subsequently the bushing 15 NOTE Write down the direction of assembiv of seal ring Write down the assembiv side of the connection notch 26 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY ASSEMBLY
13. GURE 33 Insert a new o ring 2 on the centering diameter of the arm 06 16N Position the arm on the central body A Tighten nuts 1 two stages using the criss cross method FIGURE 31 Apply onto the pinion 18 the bar hold and with the help of a torque metre check the torque of the pinion Torque 0 6 1 6 Nm If torque exceeds the maximum value then the size of shim 51 14 needs to be increased If torque does not reach the minimum value then the size of shim S1 14 needs to be reduced NOTE Make positional marks across ring nut 1 and pinion tail FIGURE 34 Install the whole differential unit ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 63 ASSEMBLY M ma Po FIGURE 35 Insert thrust block 9 of the bearing shims 8 of an initial thickness of about 1 30 mm FIGURE 36 Fit the bearing disc 9 complete with shims 8 in the intermediate cover FIGURE 37 Insert a new o ring 7 on the centering diameter of the arm Position the arm on the central body Tighten nuts 5 in two stages using the criss cross method 64 Dana Holding Corporation FIGURE 38 Apply onto the pinion a torque metre and check that torque will increase by 0 8 1 6 N m as a result of diffe rential bearing preload Example pinion torque 0 6 1 6 N m Pinion differential torque 1 4 3 2 N m FIGURE 39 Install a dial indicator as shown and shift the flan
14. IGURE 28 Fit the planetary gear 5 with bearing 6 onto the planetary gear cover 4 Using a drift insert the planetary ge ars 5 into the cover 4 FIGURE 26 Coat the screws 11 with Loctite 243 and tighten them in two stages using the criss cross method Final torque wrench setting 68 75 N m FIGURE 29 Lock into position the planetary gears 5 with the snap rings 7 A WARNING Personal injury can result when installing snap ring The appropriate safety equipment must be wom To avoid injury to your eyes wear protective glasses during this procedure 20 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 30 Fit the planetary carrier cover 2 onto the hub 3 FIGURE 31 Lock the planetary carrier cover 4 by tightening the screws 3 Torgue wrench setting for screws 20 30 N m 80 95 Nm FIGURE 32 Install the oil level plug 1 Torgue wrench setting for screws 80 95 N m ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 21 22 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual STEERING KNUCKLE EXPLODED VIEW ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 23 DISASSEMBLV DISASSEMBLV FIGURE 4 Loosen and remove the capscrews 1 from the kingpin 2 FIGURE 1 Remove the complete crown flange For details see PLANETARY REDUCTION
15. NOTE Apply a little grease to seals and cylinder ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 17 Lightly tap the cylinder head with a plastic ham mer to push it inside the cylinder NOTE Insert the head to line it up with the edge of the cylinder FIGURE 18 Introduce the stop ring and ensure that it sets in the seat of cylinder FIGURE 19 Fit the steering cylinder 5 into its seat ASM 0178E 730 563 Axle Service Manual Loctite 243 240 270 Nm FIGURE 20 Lock the cylinder 5 screws 4 using the criss cross method Applv Loctite 243 to the thread Torque wrench setting 240 270 Nm FIGURE 21 Install the predefined quote shim 6 0 3 mm in its Seat as shown in figure Do not install the shim 6 if the gap between steering cylin der and arm is less than the shim 0 3 mm Dana Holding Corporation 43 ASSEMBLY Loctite 243 240 270 N m FIGURE 22 Lock the cylinder 5 screws 4 using the criss cross method Apply Loctite 243 to the thread Torgue wrench setting 240 270 N m Loctite 270 240 270 Nm FIGURE 23 Apply LOCTITE 270 to the thread and connect the steering bars 3 by tightening the terminals onto the pi ston stem Torgue wrench setting 240 270 N m 200 220 Nm FIGURE 24 Insert the pins 2 in the steering case and lock into position using a torque wrench setting of 200 220 N m CAUTION Check that rubber gu
16. ONLY ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 9 MAINTENANCE 8 LUBRICATION MAINTENANCE POINTS 1 Oil filling plug 2 Oil draining plug 3 Check level plug 10 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual MAINTENANCE 8 LUBRICATION MAINTENANCE INTERVALS OPERATION FREQUENCY LUBRICANTS Differential Monthly Check levels Planetary reduction Every 200 hours SAE85W90 API GL4 MIL L 2105 Differential Every 1000 1200 hrs With additives for oil bath brakes Oil change Planetary reduction Every 1000 1200 hrs is recommended to set the axle s oil changes according to the machine maintenance intervals If working in heavy conditions half intervals should be used Initially after 100 working hours OPERATION MEMBER CONDITIONS FREQUENCY LUBRICANTS Greasing Articulations NLGI 3 EP ADJUSTMENT AND CHECKS FREQUENCY SERVICE BRAKE CIRCUIT Mes aus Tightening Every 200 hours Only for mineral oil use e g ATF Dexron II Make sure that master cylinder seals are suitable for mineral oil Initially after 10 working hours ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 11 MAINTENANCE 8 LUBRICATION LUBRICANT amp SEALANT SPECIFICATIONS 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 typi
17. RQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY ST 37 ST 52 M18 x 1 5 mm 330 Nm 460 Nm WHEEL NUTS WITH E INTEGRATE l M20 x 1 5 mm 490 Nm 630 N m SPHERICAL COLLAR M22 x 1 5 mm 630 Nm 740 N m FLAT COLLAR WHEEL M18 x 1 5 mm 270 Nm 360 NUTS WITH SEPARATE At M20 x 1 5 mm 360 N m 450 N m WASHER M22 x 1 5 mm 460 Nm 550 N m 20237 18 1 5 mm 260 Nm 360 Nm WHEEL NUTS WITH IN TEGRATE SEAT 1 g M20 x 1 5 mm 350 Nm 500 Nm CAPTIVE WASHER lt A LL M22 x 1 5 mm 450 Nm 650 N m RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS IT IS THE OPTIMUM MA TERIAL FOR TIGHTENING THE RIM TO THE HUB NOTE The wheel nut tightening torque is related only on nut thread and stud thread dry without oil or any lubricant NOTE The wheel nut tightening torque takes into consideration not only the nut stud characteristics but also the quality of the rim material THE DANA OFFICIAL TIGHTENING TORQUE TABLE THAT IS INCLUDED IN EACH SERVICE MANUAL SHOWS THE TORQUE FIGURE RELATED TO THE BOLT CHARACTERISTIC ONLY DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8 8 amp 10 9 STUD MATERIAL QUALITY 10 9 TIGHT TORQUE M18 x 1 5 mm M18 x 1 5 Nm 442 489 N m M20 x 1 5 mm M20 x 1 5 Nm 613 677 N m M22 x 1 5 mm M22 x 1 5 Nm 822 908 Nm THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY DANA AXLES ARE 10 9
18. ack distance FIGURE 28 Partiallv insert the long bolt 23 satellite gears 20 and spherical washers 19 FIGURE 25 Insert a new o ring on the centering diameter of the arm Position the arm on the central body Tighten nuts 27 in two stages using the criss cross method FIGURE 29 Insert the crossbolt 29 in the correct position FIGURE 26 Insert planetarv gear 18 together with washer 17 52 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 30 Satellite gears 20 spherical washers 19 and FIGURE 33 Mount the locking half box 16 onto the half box completely insert the long bolt 23 24 FIGURE 31 Bring the pin holes in line with the help of a pin FIGURE 34 Position the crown 15 on the differential carrier driver and lock it with screws 14 Insert pins 22 to end of stroke NOTE Secure the screws using the criss cross method FIGURE 32 Insert eee gear 1 8 together with washer r Loctite 243 17 104 128 Nm FIGURE 35 Use only new screws 14 pre treated with lo cking adhesive Torque wrench setting 104 128 N m ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 53 ASSEMBLY FIGURE 36 Heat the bearings 13 25 to about 100 C and fit it to the differential box 16 24 NOTE Once the bearing has cooled down lightly lubricate bea ring 13 25 with SAE85W90 oil FIGURE 38 After
19. amage the seats of both seals and piston slide FIGURE 8 Remove the snap ring of the cylinder head FIGURE 9 Continue hammering until the head is ejected from the cylinder ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 41 ASSEMBLY ASSEMBLY scraper ring seal ring FIGURE 11 After applying grease install the sealing ring of the shaft the scraper ring and the guide ring in the head guad ring FIGURE 12 Fit the seal and the backup ring onto the outside of the head 1 In order to facilitate assembly apply grease to the outer surface of the piston 2 Do not roll the seal up 3 Thoroughly check that positioning of the backup ring is correct seal ring scraper ring FIGURE 13 After applying grease install the sealing ring of the shaft and the scraper ring in the head 42 Dana Holding Corporation quad ring FIGURE 14 Prepare the piston by fitting it with the o ring and the seal guide ring In order to facilitate assembly apply grease 3 gt gt Aya i FIGURE 15 Apply grease to head seals fit the head onto the piston and push it into the cylinder using a plastic hammer Introduce the stop ring and ensure that it sets in the seat of cylinder NOTE Insert the head to line it up with the edge of the cylinder FIGURE 16 Push the piston into the cylinder using a plastic hammer
20. aorasmm fawna _ 5 rasen Jas uvum Tara tren ora zanm os 98 tson 1100 1200mm rm ou 6mm Isa mana 475 168 m 2005 2505 Nm 21 7m FINE PITCH SIZE OF BOLT TYPE OF BOLT Jess Jose Marfa 57 2 ferons sens ars szenn les menn 2 1s vesn _ 1 5 fumeur lis rann 02nn aozenn faaea LN ara 2 287 Nm Joan sonm ore senm 2 aeann aes sonm feer sonm Max mm 88 58 is sawm Jaan arotem _ 1 Sam eor TOANm jez senm fose ronm fiore morn or asin 1285 005Nm rose Horan 1511 1670 ts tez Nm 2198 2068 Nem 2302 2577 Nm 2s65 208Nm 2706 sose Nm 8 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual MAINTENANCE 8 LUBRICATION 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 TO
21. ards are intact 44 Dana Holding Corporation FIGURE 25 Center the piston by slowly moving it first in one direction then in the other and position it half way on the stro ke FIGURE 26 Apply tools 15 See drawing 5 p 70 to the hubs and lock them Using a level check that tools are perfectly flat LA p EE FIGURE 27 Without moving the piston check front and rear distance at the edge of tools Max difference 2 mm NOTE In order to check the rear distance rotate the bevel pinion and check that tools are flat ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 28 CONVERGENCY ADJUSTMENT Loosen the nuts and tighten them onto the ball and socket joints Hold the articulations still and rotate the ball and so cket joints Once the convergency has been adjusted lock the nuts Torque wrench setting for nuts 220 240 N m NOTE Adjust by the same amount on each steering rod FIGURE 29 ADJUSTING THE STEERING ANGLE Insert the end stroke screws and adjust to 59 mm ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 45 46 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DIFFERENTIAL EXPLODED VIEW ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 47 DISASSEMBLV DISASSEMBLV FIGURE 4 Remove the snap ring 11 and slowly loosen the nuts FIGURE 1 Connect a suitable lifting system Loosen and
22. be fastened onto a trestle while the other parts mentioned should rest on supporting benches 2 When removing one of the arms an anti tilting safety trestle should be placed under the other arm 3 When working on an arm that is fitted on the machine make sure that the supporting trestles are correctly po sitioned and that the machine is locked lengthways 4 Do not admit any other person inside the work area mark off the area hang warning signs and remove the igni tion key from the machine 5 Use only clean quality tools discard all worn damaged lowquality or improvised wrenches and tools Ensure that all torque wrenches have been checked and calibrated 6 Always wear gloves and non slip rubber shoes when performing repair work 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 wo
23. cal applications of each single material in order to facilitate repla cement 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 Be fore using it completely remove any lubricant by using the specific activator LOCTITE 243 The oleocompatible alternative to 242 Does not require the activation of lubricated surfaces LOCTITE 270 Anaerobic product for very high strength locking of screws and nuts Before using it completely remove any lubri cant 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 dia metrical 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
24. erously the bearing 5 and the thrust block 5 Lubricate with OPTIMOIL grease the contact surfaces of the kingpin and steering knuckle ASM 0178E 730 563 Axle Service Manual ASSEMBLY 104 128 Nm FIGURE 28 Install the kingpin 7 FIGURE 31 Tighten the new capscrews 1 of top kingpin 2 Tighten the new capscrews 6 of bottom articulation pins in in sequence using the cross tightening method sequence using the criss cross method Torque wrench setting 104 128 N m FIGURE 32 Position dial indicator preset it to 1 mm and re set it to zero FIGURE 33 Check the vertical gap using a lever FIGURE 30 Prepare a series of shims 3 of 2 5 mm to be as sembled above the upper kingpin 2 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 29 ASSEMBLY FIGURE 34 Loosen and remove the capscrews 1 from the kingpin 2 a Berg FIGURE 35 Calculate the difference between sizes First step shim Measured Backlash and Preload Draw so as to obtain the size S of the shim 3 that will go under the king pin King pin Preload Draw 0 5 0 6 mm S First step shim Measured Backlash Preload Draw EXAMPLE First step Shim 2 5 mm Measured Backlash 1 mm S 25mm 1mm 05mm 1mm FIGURE 36 Lubricate the surface of the sealing ring 4 and assemble it into position Carefully check that the rings 4 are properly oriented
25. g Corporation 61 ASSEMBLY ia Ill FIGURE 24 Connect the tension rod to the press and move FIGURE 27 Heat the outer bearing 15 to a temperature of the thrust block of the bearing 15 17 into its seat about 80C and fit it on to the pinion 18 Disconnect the press and remove the tension rod NOTE NOTE Lightly lubricate bearing 15 with SAE85W90 oil Before starting the next stage make sure that the thrust blocks has been completely inserted into its seat FIGURE 28 Install the first step pinion shims S1 14 Example S1 0 75 FIGURE 25 Heat the inner bearing 17 to about 100 and fit it to the pinion 18 NOTE In order to hold the shim 14 in position apply grease to NOTE it Once the bearing has cooled down lightly lubricate bea ring 17 with SAE85W90 oil FIGURE 29 Install the complete spacer pack onto the pinion FIGURE 26 Fit the pinion 18 in the central body 62 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY FIGURE 30 Position wrench T7 See drawing T7 p 72 onto FIGURE 32 Fit the bearing disc 4 complete with shims 3 the ring nut 1 and apply bar hold T6 See drawing T6 p 71 in the intermediate cover to the pinion 18 Stop wrench T6 See drawing T6 p 71 and rotate the nut to release it Lock the wrench and tight the nut using a torgue wrench up toa minimum reguired torgue setting of 440 490 N m FI
26. ge to check the tolerance between the bevel gear teeth Check the backlash at the input flange bolt hole B C D 60 mm Tolerance 0 29 0 39 mm FIGURE 40 Apply tool T6 See drawing T6 p 71 and remove the ring nut 10 ASM 0178E 730 563 Axle Service Manual ASSEMBLY 7 at 4 028 l FIGURE 41 Remove spacers and shims 144 je FIGURE 42 Lubricate and fit the sealing ring 13 onto tool T9 FIGURE 45 Apply Loctite 242 onto the threaded portion of See drawing T9 p 73 the pinion 18 Install the ring into the seat Screw the ring nut 10 440 490 FIGURE 43 Lubricate with grease and replace the outer o FIGURE 46 Position wrench T7 See drawing T7 p 72 onto ring 12 the ring nut 10 and apply bar hold T6 See drawing 16 p 71 to the pinion 18 Stop wrench T6 See drawing T6 p 71 and rotate the nut to release it Lock the wrench and tight the nut using a torque wrench up to a minimum required torque setting of 440 490 N m Make sure the match marks made previously line up ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 65 ASSEMBLY FIGURE 47 Caulk the ring nut 10 If the ring nut 10 is re used caulk the second position Do not re caulk the same portion 66 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual SPECIAL TOOLS 0169 8 1 5x45 2159 8 TI
27. local regulations ZA WARNING Hot oil and components can cause personal injury Avoid skin contact FIGURE 5 Use a screwdriver to remove the o ring 16 FIGURE 2 Remove the locking screws 3 of planetary cover 4 16 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 9 Tighten two M8 screws in the special threads Tighten by one turn alternately 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 10 Remove the crown 13 with crown flange 12 FIGURE 7 Remove the planetary gears 5 and the bearings 6 FIGURE 11 Remove the snap ring 14 from the crown 13 AN WARNING Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to FIGURE 8 Loosen and remove the screws 11 from the eyes wear eye protection equipment crown flange 12 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 17 DISASSEMBLV FIGURE 13 Harness the wheel hub 17 FIGURE 16 Remove the thrust blocks 15 18 from the bea Partially extract the external bearing 15 using an extractor rings and force a puller into the appropriate slots on the hub NOTE Avoid clamping or deformation of the thrust blocks FIGURE 14 Remove the external bearing 15 and the hub 17 FIGURE 17 Remo
28. ng Corporation 59 DISASSEMBLV FIGURE 13 Using an internal extractor remove the seal ring remove the inner be 13 Take care not to damage the seal ring seating l FIGURE 17 Using an internal extractor remove the thrust blocks 15 17 FIGURE 18 Using an internal extractor remove the thrust block of the internal bearing 17 as well as the shim washers 16 FIGURE 15 Extract the bearing 15 60 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 19 Check the thickness of first step pinion shims 16 Example 1 1 mm FIGURE 20 Check nominal dimension B as marked on the old pinion Execute the calculation following the indicated formula to ob tain the necessary value to the successive calculation EXAMPLE 1 1 0 1 1 mm C 1 mm ASM 0178E 730 563 Axle Service Manual FIGURE 21 Check nominal dimension D as marked on the new pinion Execute the calculation following the indicated formula to ob tain the value of necessary shims S 0 Example 1 0 1 0 9mm 0 9 mm FIGURE 22 Partially insert the thrust block of the bearings 15 17 NOTE The smaller shims 10 must be placed in between the thi cker ones FIGURE 23 Install tension rod and guidetool T8 See drawing 18 p 72 on the thrust block of the external 15 and inner 17 bearing Dana Holdin
29. rawings 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 SPICER ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 5 MAINTENANCE 6 LUBRICATION DEFINITION OF VIEWPOINTS LEFT SIDE m RIGHT SIDE LATO SINISTRO LATO DESTRO LINKE SEITE RECHTE SEITE LADO IZQUIERDO LADO DERECHO COTE GAUCHE COTE DROITE DATA PLATE MFG BY DANA ITALIA S p A MADE IN COMO ITALY 1 Type and model unit modification index 2 Differential type 3 Reduction ratio 4 Serial number 5 Axle number 6 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual MAINTENANCE 8 LUBRICATION CONVERSION TABLES UNITS OF PRESSURE 1 1 BAR 10 PA 14 4 PSI UNIT OF WEIGHT ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 7 MAINTENANCE 8 LUBRICATION TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TVPEOF BOLT JO e ET Meximm os msnn aanren Mertasmm 238 282 fss 2ann fa wanm far wsnm ioxismm mann Jeram 0 is sawm fis renm etd zz jerzawn _ mexem 200 inm ao enm ass sieum for sron forum _ les sina nasa Jas sioun M
30. remove the screws 27 securing the arm to the body Remove the arm FIGURE 5 Remove the spring guide sleeve 10 and the pi ston return spring 8 FIGURE 2 Insert an M14 threaded rod in the arm correlated with a swab from the appropriate diameter and a hard stop E lt FIGURE 6 Note the position of assembly Slowly introduce compressed air via the differential lock inlet to extract the piston 5 FIGURE 3 By acting on the buffer spring guide sleeve 10 tighten the nuts on the threaded rod compressing the spring 8 This operation is postentially dangerous Retain the piston as it may be expelled rapidly and damaged 48 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 7 Using a screwdriver remove the stop ring 2 and the spacer 3 FIGURE 11 Extract the bearings 13 25 from the differential carrier If disassembly is carried out in order to replace crown wheel and pinion bearings or planetarv gear break up distance washers and calculate clearances as indicated in the sec tions regarding removal disassembiv assembiv and instal lation of differential unit and bevel pinion FIGURE 9 Remove rings 4 6 from cvlinder NOTE 1 All seals must be replaced every time the unit is disas sembled 2 Particular attention must be paid not to damage the seats of both seals and piston slide FIGURE 12 Remove the capscrews 14 of the crown
31. rk 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 Indicates an imminently hazardous situation which if DANGER not avoided will result in death or serious injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury NOTICE Indicates a situation which if not avoided may result in if not avoided may result in damage to components ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 13 14 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual PLANETARY REDUCTION GEAR EXPLODED VIEW 7 19 ASM 0178E 730 563 Axle Service Manual Dana Holding Corporation 15 DISASSEMBLV DISASSEMBLV AN CAUTION Perform all operations on both arms TAREN FIGURE 3 Disjoin the spider cover 4 from the hub by alter natively forcing a screwdriver into the appropriate slots FIGURE 1 Remove the oil level plug 1 Drain oil AN CAUTION 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
32. tract the whole differential unit FIGURE 1 Connect a suitable lifting svstem Loosen and remove the screws 5 securing the arm to the bodv Remove the arm FIGURE 5 Connect a suitable lifting svstem Loosen and remove the screws 1 securing the arm to the bodv Remove the arm FIGURE 6 Use a screwdriver to remove the o ring 2 FIGURE 3 Bv means of a puller remove the thrust block of the bearing 8 from the arm Remove the shims 9 located under the outer thrust block of the bearing 8 58 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual DISASSEMBLV FIGURE 7 By means of a puller remove the thrust block of the bearing 4 from the arm Remove the shims 3 located under the outer thrust block of the bearing 4 LI fa a AN 5 11 fi 1 ng 4 lee FIGURE 11 Remove spacer 11 and shims 14 FIGURE 8 Remove the calking in order to preserve the screw cutting of the pinion during the ring nut 10 removal FIGURE 12 Use a screwdriver to remove the o ring 12 FIGURE 9 Position wrench T6 See drawing T6 p 71 onto the ring nut 8 and apply bar hold T7 See drawing T7 p 72 to thepinion 13 Stop wrench T6 See drawing 16 p 71 and rotate the pinion so as to release and remove the ring nut 3 NOTE If disassembly proves awkward weld the ring nut at ap proximately 80 C ASM 0178E 730 563 Axle Service Manual Dana Holdi
33. ve the internal bearing 18 18 Dana Holding Corporation ASM 0178E 730 563 Axle Service Manual ASSEMBLY ASSEMBLY press the thrust blocks 15 18 into the hub 17 all the way down FIGURE 20 Position the sealing ring 19 in the special tool T2 See drawing T2 p 67 Position tool T2 See drawing T2 p 67 and press the sealing ring 19 into its seat NOTE Check that the ring 19 is correctly oriented Flat surface should be visible after mounting ASM 0178E 730 563 Axle Service Manual FIGURE 21 Install the inner bearing 15 NOTE Using a plastic hammer drive the bearing to the limit stop by lightly hammering around the edge FIGURE 22 Install the crown wheel 13 FIGURE 23 Insert the snap ring 14 in order to fix the flange 12 in the crown 13 Personal injury can result when installing snap ring The appropriate safety equipment must be wom To avoid injury to your eyes wear protective glasses during this procedure Dana Holding Corporation 19 ASSEMBLY FIGURE 24 Match up the punch marks on the joint case and the crown wheel carrier flange FIGURE 27 Insert a new o ring 16 on the centering diameter of wheel hub NOTE In order to hold the o ring 16 in position apply grease to FIGURE 25 Fit the complete crown flange 12 In order to fasten the flange 12 use a plastic hammer and alternately hammer on several equidistant points F
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