Service Manual
Contents
1. f N 09 SCREW M10 03 MS Ex LE Mi 08 SCREW 8 03 5 07 STOP 0 5 06 TUBE HANDLE 0 VS 05 STUD 02 IS 04 MAGEN 0 5 03 BUMPER 0 MS u u 02 DRIVER 0 MS m H N Ta Bp c 52 01 BASE MAIN 0 5 m 1 NO am cg DESCRIPTION QTY ATL REMARK Q M er DIN ee 2 7 E p ER HANDLE com l cU l EN acm 4 i c I J f N e 2 0 ed Nel 18 946 EE TO p qu oO TEN l 10 40 N V V V c J M2. 25 Steering Cylinder Installation 26 Axle Trunnion Installation 26 Axle Installation amp End Play Adjustment 28 Toe in Adjustment users 28 Driveshaft amp Hydraulic Line Installation 28 SPE GIA 29 Face Seal Tool SEG OE 29 Face Seal Cup Driver 31 Final Drive Spanner Nut Socket 32 Steering Cylinder amp Tie Rod Removal Tool 33 Final Drive Bracket Tool 34 Spacer Seal Tool ans ES Fe RE cec 35 Pinion Bearing Cup Tool 36 Backlash Measurement Tool 37 Welch Plug Driver Tool 38 ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation MAINTENANCE amp LUBRICATION Data Plate Model Number Build Date DDMMYY Serial Number E ch Definition of Viewpoints UI i ILI l 4 ee mas i LEFT SIDE n 1 Dana Holding Corporation of CA email H is Eu RE i i Act e J N Si i p listb d F EE A
3. VBS 3NUS SCREWED WITH M8 ALLEN SCREW ASM 0190 520 7127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 34 Spacer Seal Tool Spacer Seal Tool 37 81 262 06 i 256 00 N re 41 81 t 7 00 13 90 5 00 3 50 70 00 42 31 i ZS 142 50 880 00 Pr 264 00 9 242 00 NURLING OIL SEAL ASSEMBLY TOOL MAT 20MnCr5 CASE HARDEN 55 60 HR 35 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Pinion Bearing Cup Tool Bearing Cup Tool 04 5000 59 3000 1 39 0000 63 9000 PINIUN INNER AND UUTER PRESSING TUUL ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 36 Backlash Measurement Tool Backlash Measurement Tool Section AA Section AA 19 lt Pa 11 52 50 45 00 E 7 0 Slitting up to centerline 2 mm Slitting up to centerline 2 mm E NOE 24 34 18 77 4 Tap X 4 Nos 7 245 00 ED ASSEMBLY OF TWO PIECES BACKLASH MEASURING TOOL MAT 20MnCr5 CASE HARDEN 55 60 HR 37 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Welch Plug Driver Tool Welch Plug Driver Tool
4. re RIGHT SIDE lt gt DIRECTION ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Maintenance Points Maintenance Points Front Trunnion Rear Trunnion 45 Mme DI __ EE TA Le Ek E se Ed EE N agn ELE ha tHE EE ES Eur Hi He XI poem PEN E gt WIE me 07 st H N MEI J sal 1 Oil fill plug 2 Oil drain plug 3 Check level plug 4 Grease zerk 5 Front trunnion thrust bolt Maintenance Intervals EER Check Levels rt 50 hours check level on dipstick Joc Oil Change Axle Initially after 100 working hours Every 600 hours Greasing Front amp Rear Trunnion Dry land applications 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 48 55 Ibs ft 65 75 Nem Wheel Nuts Initially after 10 working hours Every 200 hours ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual DanaHolding Corporation 2 SAFETY PRECAUTIONS 10 11 12 13 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 worki
5. The end play sets backlash to 0 005 0 007 in 0 13 0 18 ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 10 Knuckle Housing Removal FIGURE 31 4 Remove spanner locknut star lockwasher bear ing cone FIGURE 29 8 Apply Loctite 380 480 to a new welch plug l and install to Knuckle housing using the Welch Plug Driver Tool page 38 The welch plug should always be replaced Do not reuse Knuckle Housing Removal 1 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 32 5 Remove knuckle housing from shoulder housing FIGURE 30 3 Straighten tabs on star lockwasher that secure span ner nut in slot Loosen the spanner locknut using the Final Drive Spanner Nut Socket page 32 11 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Knuckle Housing Installation Knuckle Housing Installation FIGURE 33 6 Remove face seal assembly and bearing cone Press off bearing cups from knuckle if necessary Clean and inspect all parts replacing any damaged compo nents FIGURE 34 7 Install bearing cups E amp G into knuckle using appro priate drivers FIGURE 35 8 Install bearing cone D into knuckle housing 9 Install face seal cup C using the Face Seal Cup Driver page 31 The fa
6. capscrews to 22 28 lbs ft 30 38 Nem ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 8 Drop Shaft Disassembly Drop Shaft Disassembly FIGURE 19 l MA FIGURE 22 4 Remove bevel gear from drop shaft 1 Carefully remove welch plug from knuckle housing M _ FIGURE 20 EE FIGURE 23 5 Remove snap ring from knuckle housing 2 Remove snap ring from drop shaft 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 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Drop Shaft Assembly amp Installation Drop Shaft Assembly amp Installation FIGURE 25 7 Remove 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 assembly in final drive housing 3 Install internal snap ring D in final drive housing 4 Install bevel gear 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 a FIGURE 28 7
7. 7 Grease the rear trunnion after installation using the grease zerk G until grease purges out from the v ring Assemble Front Trunnion FIGURE 98 2 Install o ring E inside the rear trunnion F bore 12 o clock position FIGURE 99 FIGURE 102 3 Insert the rear bushing D on the rear trunnion 1 Install bushing B in front trunnion A Ensure the hole in the bushing is oriented in the 12 o clock position 4 Install v ring and v ring seal B on center section pin 2 Install the thrust plate on the front trunnion It might be necessary to apply grease to thrust plate 5 Install the thrust washer on the rear trunnion F to hold it in place bore It might be necessary to apply grease to the 3 Install v ring and v ring seal D on center section E pin 4 Slide front trunnion A on center section E pin thrust washer to hold it in place FIGURE 100 6 Slide rear trunnion F on center section A pin 27 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Axle Installation amp End Play Adjustment Axle Installation amp End Play Adjustment FIGURE 103 Install axle into vehicle 2 Install front trunnion hex nut B loosely on bolt A 3 Thread bolt A into front trunnion C and tighten to 11 22 Ibs ft 15 30 Nem 4 Tighten the jam nut B tight against the front trunnion C to a torque
8. NOTE It may be necessary to pry the cover from the housing using the two pry bars on each side of the cover T s ME mr L p 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 Dana Holding Corporation 6 Final Drive Cover Disassembly FIGURE 14 7 f necessary press bearings off of bevel gear and output shaft FIGURE 11 4 Remove 41T bevel gear from output cover 9 o FIGURE 12 5 Remove the output cover FIGURE 15 8 Clean and inspect all parts replacing any damaged components FIGURE 13 6 Remove face seal from the output cover and the out put shaft Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Final Drive Cover Installation Final Drive Cover Installation A Spindle Nut B Retainer Plate 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 2 Install the bearing cone J to the output shaft L FIGURE 17 FIGURE 16 c Assemble the shim washer and USE
9. pinion nut N FIGURE 84 14 Remove the four 4 bolts used for the temporary assembly and remove the left hand trumpet arm FIGURE 88 18 Install new o ring J The o ring J should always be replaced Do not reuse FIGURE 85 15 Apply Hylomar M Optional Loctite 515 evenly to the surface of the trumpet housing FIGURE 89 19 Install a new oil seal K using the Spacer Seal Tool page 35 to sure ensure the seal seats correctly FIGURE 86 16 Install the short housing to the long housing by applying Loctite 262 to all capscrews and torquing to 50 55 Ibs ft 68 75 Nem The oil seal L should always be replaced Do not reuse ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 24 Drain Plug Installation 4 FIGURE 90 20 Install spacer L slinger M and NEW pinion nut N Apply Loctite 272 to pinion nut threads and tighten to 100 118 Ibs ft 135 160 Nem Drain Plug Installation FIGURE 91 1 Apply Loctite 565 to center housing drain plug threads left photo above and tighten to 15 20 Ibs ft 20 27 Nem Apply Loctite 565 to wheel end drain plug threads right photo above and tighten to 7 10 Ibs ft 9 5 13 5 Nem Then fill final drive housings and main axle with 5 5L 1 45 gal J20C oil E FIGURE 92 2 Verify the oil level is between the MIN and MAX level on the dipstick Avoid Damage Allow oil one h
10. x N Pinion Nut Pinion Assembly Number 1 Assemble bearing cone to pinion FIGURE 73 b If ring and pinion or bearing are being replaced notice the or number P on the end of pinion or on pinion stem This indicates the best FIGURE running position of each particular gear set in 2 Place inner shim s E under bearing cup D to set thousandths of an inch If the number on the pinion height new set is not the same as the number on the one being replaced adjust the height by adding or removing inner shim s B from original shim pack according to dimension etched on the end of pinion or on pinion stem a If the original pinion and bearing are being used use the original shims or install new shims the same thickness as original shims Example 1 If the old pinion reads 4 and the new pinion is marked O add 0 004 in shims to the original pack Example 2 If the old pinion reads 2 and the new pinion is marked 1 add 0 003 in shims to the original pack 21 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Center Section Assembly amp Installation FIGURE 77 6 Install the spacer L slinger M amp OLD pinion nut N opacer bore chamfer should be towards o ring FIGURE 74 3 Using a Pinion Bearing Cup Tool page 36 assemble bearing cups D amp H and shims E in the housing A Y FIGURE 78 7 Tighten the old pinion nut t
11. 285 314 Nem 1 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Center Section Removal amp Disassembly Center Section Removal amp Disassembly 1 Before removing the differential remove the drive shaft see page 4 axle see page 5 steering cylin der see page 5 tie rods see page 6 and right hand and left hand wheel end assemblies FIGURE 59 5 Remove the shim and bearing cup from the right FIGURE 56 hand trumpet arm 2 Remove axle shafts T FIGURE 60 FIGURE 57 6 Remove the differential assembly from left hand 3 Keep the left hand trumpet arm on proper support trumpet arm Remove capscrews from the arm Right hand Trumpet FIGURE 61 Left hand 7 Remove the shim and bearing cup from the left hand Trumpet trumpet arm FIGURE 58 4 Remove the right hand trumpet arm from the center section 5 0190 520 2127 1 S20BZ130 1 Axle Service Manual Dana Holding Corporation 18 Center Section Removal amp Disassembly Pinion Disassembly FIGURE 62 8 Press off both bearings if necessary Then remove I I FIGURE 63 ring gear capscrews and ring gear from differential case 10 Loosen pinion nut NOTE The differential case and internal parts come as an assem bly If any damage is apparent there is no need to disas semble the case as the whole assembly must be replaced 9 Clean and inspect all parts replacing any
12. 8X35 9 i A e aD A ES ON ols 16 N 35 19 ua LI ES di BUM JO 930 90 6 B 20030 8 x M P au 5 60 El 136 ASM 0190 520 2127 1 8 S20BZ130 1 Axle Service Manual Dana Holding Corporation 38
13. D spindle nut to output shaft and tighten the nut to 330 3 Using the Face Seal Tool page 29 install the face 360 Ibs ft 447 2 488 Nem seal K on the final drive cover H and output shaft d Using the Final Drive Bracket Tool page 34 L See Face Seal Installation on page 14 for verify the rolling torque of the final drive cover is cleaning of face seal 54 76 Ibs in 6 1 8 6 Nem 4 Install the final drive cover H to the output shaft L e lf the rolling torque is not correct reselect shims to achieve the correct rolling torque Install the bearing cone E to the bevel gear D f If the rolling torque is correct remove the USED 6 Install the bevel gear D to the final drive cover and spindle nut Using a NEW spindle nut B apply output shaft assembly H amp L Install new o ring G on final drive cover H 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 thread lock to the threads and tighten nut to 330 360 Ibs ft 447 2 488 Nem n iua er until final assembly as this nut is torque prevailing FIGURE 18 9 Install final drive cover to knuckle housing tightening
14. E When removing the rear trunnions also remove the o ring thrust washer and the v ring on the housing Inspect the o ring and replace if damaged When removing the front trunnion also remove the v ring and thrust washer 5 Dana Holding Corporation Steering Cylinder Removal FIGURE 3 1 Remove cotter pins castle nuts and washers FIGURE 4 2 Remove steer cylinder le NOTE Oylinder ball end studs are tapered Use a Steering Cylinder amp Tie Rod Removal Tool page 33 to avoid damaging threads if cylinder is to be reused ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Tie Rod Removal Tie Rod Removal FIGURE 5 1 Remove the cotter pin and the castle nut from tie rods b u 7 FIGURE 6 2 Using a tie rod end removal tool remove rod ends from knuckles NOTE Tie rod ball end studs are tapered Use a Steering Cylinder amp Tie Rod Removal Tool page 33 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 ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Final Drive Cover Disassembly ka FIGURE 8 1 Remove capscrews from final drive cover 2 FIGURE 9 2 Separate final drive cover and output shaft from final drive housing 19
15. Z130 1 Axle Service Manual Shoulder Housing Assembly Shoulder Housing Assembly A Snap Ring B Shim C Bearing FIGURE 52 D Bevel Gear 121 I E Bevel Gear 15T 3 Install internal snap ring A into shoulder housing G F Bearing NOTE G Shoulder Housing SS Do not install shims B until backlash measurements are FIGURE 49 taken FIGURE 50 1 Install bearing F and lower bevel gear 15T E into shoulder housing FIGURE 53 4 Measure end play of the upper shoulder gear To set the end play a Measure distance between the bearing C and the snap ring A at several locations b Assemble shims B 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 0 10 0 20 mm FIGURE 51 2 Install bearing upper bevel gear 12T D into shoulder housing ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 16 Shoulder Housing Assembly FIGURE 54 5 Apply Hylomar M Optional 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 Ai i FIGURE 55 6 Install capscrews fastening the shoulder housing to the axle housing and tighten to 210 2 231 5 Ibs ft
16. al inner diameter and seal contact band is less than 5096 of the distance between the seal inner diam eter and the outer diameter FIGURE 41 9 Then apply a coat of clean MS8 oil to the metal seal faces with a lint free applicator The oil must not wet 4 Place the seal in the Face Seal Tool page 29 and surfaces other than the sealing faces locate this assembly squarely against the top of the conical seal 10 Clean the metal surfaces with lint free cloth 1 MS8 oil is mineral based oil ranging from 10W to 90W ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual 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 47 5 Remove bearing and lower shoulder 15T gear assembly from shoulder housing FIGURE 44 2 Remove four capscrews fastening shoulder housing to axle housing JA FIGURE 45 3 Remove the internal snap ring and any shim s from shoulder housing FIGURE 48 6 If necessary press off gear from bearings Clean and inspect all parts replacing any damaged compo nents FIGURE 46 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 0190 520 2127 1 amp S20B
17. ce seal cup C should always be replaced Do not reuse 5 0190 520 2127 1 S20BZ130 1 Axle Service Manual Dana Holding Corporation 12 Knuckle Housing Installation FIGURE 36 10 Install face seal C using the Face Seal Tool page 29 See Face Seal Installation on page 14 FIGURE 37 11 Lubricate knuckle housing FIGURE 38 12 Install knuckle housing on shoulder assembly 13 Lubricate and install bearing cone H 13 Dana Holding Corporation 14 15 Install star lockwasher Add Loctite 277 to spanner nut J threads and install using Final Drive Spanner Nut Socket page 32 and torque to 66 74 lbs ft 90 100 Nem 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 this step a minimum of 4 times until the nut will no longer advance FIGURE 39 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 1 should always be replaced Do not reuse 17 18 Install drop shaft See Drop Shaft Assembly amp Installation on page 10 Install final drive cover See Final Drive Cover Instal lation on page 8 ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Face Seal In
18. damaged components r FIGURE 64 11 Remove the nut and slinger DO NOT discard nut at this time The pinion nut is a 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 tighten correctly FIGURE 65 12 Remove spacer 19 Dana Holding Corporation ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Center Section Removal amp Disassembly FIGURE 69 16 Remove both bearing cups being careful not to dam age housing surface FIGURE 66 13 Remove oil seal and bearing cone FIGURE 70 17 Remove shim with inner bearing cup FIGURE 67 14 Remove o ring FIGURE 68 15 Remove pinion bearing pinion bearing spacer and shim from housing NOTE The ring gear and pinion gear are a matched set and are serviced as an assembly If either the ring gear or pinion has FIGURE 71 wear or damage both must be replaced 18 Clean and inspect all parts replacing any damaged components 5 0190 520 2127 1 S20BZ130 1 Axle Service Manual Dana Holding Corporation 20 Center Section Assembly amp Installation Center Section Assembly amp Installation A Housing B Pinion C Bearing Cone D Bearing Cup E Inner Pinion Shim F Pinion Bearing Spacer G Pinion Bearing Preload Shim H Bearing Cup l Bearing Cone J O ring M K Oil Seal N L Spacer M Slinger
19. ng on an arm that is fitted on the machine make sure that the supporting trestles are correctly posi tioned 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 dynamometric 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 to the relative law provisions obtaining in the country where the axles are being over hauled 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 for After repair wo
20. o 100 118 Ibs ft 135 160 Nem 8 Check the rotation of the pinion a Verify the pinion rotation torque is 10 15 Ibs in FIGURE 75 1 13 1 69 Nem 4 Install the pinion with bearing B amp C spacer F and b If the pinion does not turn within specification shim G adjust the shim pack G Add shims if rotation NOTE torque is too high remove shims if rotation VU Ad S EE EE a EE EE EE torque is too low Number on pinion and ring gear indicate matched set Make sure numbers on ring and pinion gears match before assem bling FIGURE 76 5 Install the bearing cone l ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 22 Center Section Assembly amp Installation A Shim B Bearing Cup C Bearing Cone D Ring Gear E Differential F Ring Gear Bolts G Bearing Cone H Bearing Cup Shim FIGURE 79 FIGURE 80 9 Install the ring gear D to the differential E tightening the ring gear bolts F to 58 65 Ibs ft 79 88 Nem NOTE Bolts used to fasten differential and ring gear are special bolts and should be replaced after disassembly FIGURE 81 10 Install the shim A and bearing cup B into center section The bearing shim s control the ring and pinion backlash and the preload of the differential bearings 23 Dana Holding Corporation There may be several shims on each differential case Whatever shim thicknes
21. oervice Manual lt pana gt SPICER Off Highway Products Axle S20B 127 1 520 7130 1 ASM 0190 March 2014 5 MAINTENANCE 8 LUBRICATION 1 Data Plate niit 1 Definition of Viewpoints 1 Maintenance Points 2 Maintenance Intervals 2 SAFETY PRECAUTIONS iis des 3 DISASSEMBLY amp REASSEMBLY 4 EXploded VIEW anne 4 Driveshaft amp Hydraulic Line Removal 5 Axle Removal nase 5 Steering Cylinder Removal 5 Tie Rod Removal ha 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 Center Section Removal amp Disassembly 18 Center Section Assembly 8 Installation 21 Drain Plug Installation 25 Tie Rod Installation
22. of 48 55 Ibs ft 65 75 Nem Grease Zerk FIGURE 104 5 Grease the front trunnion after installation using the grease zerk D until grease purges out from the v ring Toe in Adjustment le NOTE The toe in adjustment must be performed on the vehicle 1 Jack up 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 le NOTE One of the tie rod ends and jam nut has left hand threads FORWARD TOE IN SETTING DIFFERENCE IN LENGTHS B A TO BE 3 0mm 0 0mm FIGURE 105 3 Measure and record the distance between the lines at the front and the rear of the tire at 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 using a wrench to increase or decrease the amount of toe until the measured dimension is 0 0 125 in 0 3 mm between the front and rear 5 Apply Loctite 262 and tighten the jam nuts to 116 124 Ibs ft 157 168 Nem Driveshaft amp Hydraulic Line Installation 1 Position driveshaft onto machine While supporting drive shaft slide splined connector toward machine 2 Install spring pin to drive shaft splined connector 3 steering cylinder hydraulic lines ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 28 SPECIAL TOOLS Face Seal To
23. ol Left Hand Side 29 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Face Seal Tool Right Hand Side 5 0190 520 2127 1 S20BZ130 1 Axle Service Manual Dana Holding Corporation 30 Face Seal Cup Driver Face Seal Cup Driver 100 0109 6 0 1 3 9 20 DOLLY FOR FACE SEAL CUP PRESSING MATL MS QTY INO 31 Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Final Drive Spanner Nut Socket Final Drive Spanner Nut Socket OT SOCKET MAIL EN 8 TOUGHENED QTY A2NOS PINION NUT TORQUING SHOULDER 025 10 3i 5003 1 ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual DanaHolding Corporation 32 Steering Cylinder amp Tie Rod Removal Tool Steering Cylinder amp Tie Rod Removal Tool 33 2 54 Dana Holding Corporation 0 625 18 UNF 2A THD 45 16 227919791919 5 555 525 0000000600 0606 LESS 10 TIE ROD amp CYLINDER REMOVING TOOL MATL EN8 A F 32 ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Final Drive Bracket Tool Final Drive Bracket Tool 01 MATL EN 8 TOUGHENED SNOS DRIVE SHAFT TTR CHECKING PLATE WO 074 10 78 43 110 92 01 PLATE T MATL MS my QTY 1NO DRIVE SHAFT TTR CHECKING PLATE WO 074 10
24. our to settle before checking level to ensure accurate dipstick reading Then repeat oil check after several hours of operation 25 Dana Holding Corporation ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Tie Rod Installation Tie Rod Installation Steering Cylinder Installation Steering Cylinder Boots FIGURE 96 1 Inspect steering cylinder boots replacing as needed Tie Rod Boots FIGURE 94 1 Inspect tie rod end boots replacing boots as needed 2 Insert tie rod ends into holes in knuckle arms FIGURE 97 2 Install cylinder and secure with washers and castle nuts Torque castle nuts 84 8 94 4 Ibs ft 115 128 Nem and install cotter pins If slots in castle nut do not line up with cotter pin holes continue tightening nut until next slot aligns FIGURE 95 3 Install castle nuts to tie rod ends and tighten to 85 94 Ibs ft 115 128 Nem NOTE Only grease tie rods if grease zerk is present 4 Install cotter pins If slots in castle nuts do not align with holes after torquing tighten nuts until next slot aligns 5 Adjust toe in See Toe in Adjustment on page 28 6 Install wheel and tire to final drive ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual Dana Holding Corporation 26 Axle Trunnion Installation Axle Trunnion Installation 1 Raise front axle off ground to take weight off front axle Assemble Rear Trunnion FIGURE 101
25. rk has been completed accurately touch up any coated part that 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 DANGER avoided will result in death or serious injury Indicates an imminently hazardous situation which if not avoided could result in death or serious injury Indicates a situation which if not avoided may result in damage to components Indicates information which may make product service NOTICE easier to perform Dana Holding Corporation ASM 0190 520 2127 1 amp S20BZ130 1 Axle Service Manual DISASSEMBLY amp REASSEMBLY Exploded View 4 Dana Holding Corporation ASM 0190 S20BZ127 1 8 S20BZ130 1 Axle Service Manual Driveshaft amp Hydraulic Line Removal Driveshaft amp Hydraulic Line Removal Disconnect the steering cylinder hydraulic 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 1 1 Remove axle completely supporting the axle with a hoist and remove front wheels Place the axle on workbench or blocks to disassemble Bushings gt gi FIGURE 2 2 Remove front and rear trunnions Inspect axle bushings and replace if required NOT
26. s is added to one side of the differ ential case must be removed from the other side Or what ever shims are removed from one side must be added to the other to keep bearing preload from changing a If differential bearings C amp G were not removed place original shims A amp l or new shims equaling the same thickness on the same side of the differential assembly from which they were removed b If the differential case bearings or gear set are being replaced set the bearing preload and gear backlash by adding or removing shim s between the ring gear side bearing and differential case Shim the bearings until preload is 1 5 3 Ibs ft 2 4 Nem FIGURE 82 11 Install the differential case assembly to the carrier housing 12 Check gear backlash with a dial indicator is 0 010 0 015 in 0 25 0 37 mm at pinion Start end FIGURE 83 13 Install the shims I and bearing cup H in the arm Temporarily assemble the left hand trumpet arm with 4 bolts and check the backlash and pre load using the Backlash Measurement Tool page 37 If backlash IS CORRECT continue to Step 14 If backlash IS NOT CORRECT remove the left hand trumpet arm then recalculate and select the necessary shims to obtain the correct backlash and pre load ASM 0190 S20BZ127 1 amp S20BZ130 1 Axle Service Manual Center Section Assembly amp Installation N FIGURE 87 17 Remove spacer L slinger M and old
27. stallation 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 non petroleum based solvent Dry with a FIGURE 42 clean wipe 5 Spray the o ring and seat with isopropyl alcohol to 2 Clean face seal o ring with isopropyl alcohol spray act as a lubricant to the o ring prior to installation to remove any 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 the rubber o ring on the seal ring ensure that it is uniformly seated on the retaining lip and is not twisted EN T FIGURE 43 6 Use sudden and even pressure to push in the seal FIGURE 40 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 40 8 After installing the seal halves wipe both metal seal ing faces clean with a lint free cloth le NOTE Metal face seals should be replaced when the distance between the se
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