Axle 223 ASM-0029E

Service Manual
Axle 223
ASM-0029E
September 2015
CONTENTS
INTRODUCTION ................................................................................................................................ 5
SPECIFICATIONS .............................................................................................................................. 7
DEFINITION OF VIEWPOINTS ...................................................................................................................... 7
DATA PLATE ................................................................................................................................................. 7
CONVERSION TABLES ................................................................................................................................ 8
UNITS OF PRESSURE ............................................................................................................................. 8
UNIT OF WEIGHT .................................................................................................................................... 8
UNITS OF TORQUE ................................................................................................................................. 8
TORQUE SPECIFICATIONS ......................................................................................................................... 9
COARSE PITCH ....................................................................................................................................... 9
FINE PITCH .............................................................................................................................................. 9
WHEEL NUT TIGHTENING TORQUES ......................................................................................................... 10
MAINTENANCE ................................................................................................................................. 11
MAINTENANCE POINTS .............................................................................................................................. 11
OIL DRAINING MANDATORY PROCEDURE ................................................................................................ 12
CENTRAL HOUSING ............................................................................................................................... 12
PLANETARY GEAR REDUCTION ............................................................................................................ 12
MAINTENANCE INTERVALS ........................................................................................................................ 13
LUBRICANT & SEALANT SPECIFICATIONS ................................................................................................ 14
SAFETY PRECAUTIONS ................................................................................................................... 15
PLANETARY REDUCTION GEAR .................................................................................................... 17
EXPLODED VIEW .......................................................................................................................................... 17
DISASSEMBLY ............................................................................................................................................. 18
ASSEMBLY ................................................................................................................................................... 22
SPECIAL TOOLS .......................................................................................................................................... 26
T1 ............................................................................................................................................................. 26
T2 ............................................................................................................................................................. 26
T3 ............................................................................................................................................................. 27
T4 ............................................................................................................................................................. 28
T5 ............................................................................................................................................................. 29
T6 ............................................................................................................................................................. 29
COMPLETE STEERING CASE .......................................................................................................... 31
EXPLODED VIEW .......................................................................................................................................... 31
DISASSEMBLY ............................................................................................................................................. 32
ASSEMBLY ................................................................................................................................................... 33
STEERING CYLINDER ...................................................................................................................... 35
EXPLODED VIEW .......................................................................................................................................... 35
DISASSEMBLY ............................................................................................................................................. 36
ASSEMBLY ................................................................................................................................................... 39
SPECIAL TOOLS .......................................................................................................................................... 45
T1 ............................................................................................................................................................. 45
T2 ............................................................................................................................................................. 45
U-JOINT ............................................................................................................................................. 47
EXPLODED VIEW .......................................................................................................................................... 47
DISASSEMBLY ............................................................................................................................................. 48
ASSEMBLY ................................................................................................................................................... 49
SPECIAL TOOLS .......................................................................................................................................... 50
T1 ............................................................................................................................................................. 50
T2 ............................................................................................................................................................. 50
ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 3

BRAKE WEAR CHECK PROCEDURE .............................................................................................. 51
OLD VERSION ......................................................................................................................................... 51
NEW VERSION ........................................................................................................................................ 53
SPECIAL TOOLS .......................................................................................................................................... 54
T1 ............................................................................................................................................................. 54
SERVICE BRAKE AND NEGATIVE PARKING BRAKE .................................................................... 55
EXPLODED VIEW .......................................................................................................................................... 55
DISASSEMBLY ............................................................................................................................................. 56
ASSEMBLY ................................................................................................................................................... 60
RELEASE ...................................................................................................................................................... 67
ADJUST ........................................................................................................................................................ 67
DIFFERENTIAL UNIT ........................................................................................................................ 69
EXPLODED VIEW .......................................................................................................................................... 69
DISASSEMBLY ............................................................................................................................................. 70
ASSEMBLY ................................................................................................................................................... 74
SPECIAL TOOLS .......................................................................................................................................... 79
T1 ............................................................................................................................................................. 79
BEVEL PINION ................................................................................................................................... 81
EXPLODED VIEW .......................................................................................................................................... 81
DISASSEMBLY ............................................................................................................................................. 82
ASSEMBLY ................................................................................................................................................... 85
SPECIAL TOOLS .......................................................................................................................................... 90
T1 ............................................................................................................................................................. 90
T2 ............................................................................................................................................................. 91
T3 ............................................................................................................................................................. 91
T4 ............................................................................................................................................................. 92
T5 ............................................................................................................................................................. 93
LIMITED SLIP DIFFERENTIAL UNIT ................................................................................................ 95
EXPLODED VIEW .......................................................................................................................................... 95
DISASSEMBLY ............................................................................................................................................. 96
ASSEMBLY ................................................................................................................................................... 98
SWINGING SUPPORT ....................................................................................................................... 101
EXPLODED VIEW .......................................................................................................................................... 101
DISASSEMBLY ............................................................................................................................................. 102
ASSEMBLY ................................................................................................................................................... 103
SERVICE BRAKE ............................................................................................................................... 105
EXPLODED VIEW .......................................................................................................................................... 105
DISASSEMBLY ............................................................................................................................................. 106
ASSEMBLY ................................................................................................................................................... 109
4 Dana Holding Corporation ASM-0029E - 223 Axle Service Manual

INTRODUCTION
The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient re-
pair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a com-
plete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual
components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photogra-
phs and diagrams illustrating the various phases of the operations, allows accurate work to be performed.All the information
needed for correct disassembly, checks and assembly of each individual component is set out below. In order to remove the
differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the fol-
lowing operations it is presumed that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equip-
ment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and specific spanners or
wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any en-
crusted or accumulated grease.
INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate products
and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly check the condition of
all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (o-rings, oil shields) which are subject to
major stress and wear. In any case, it is advisable to replace the seals every time a component is overhauled or repaired. During
assembly, the sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion, replacement of
one component requires the replacement of the other one. During assembly, the prescribed pre-loading, backlash and torque
of parts must be maintained.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair work can
be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or directly from the Service
Centers or Authorized Distributors of SPICER.

SPECIFICATIONS
DEFINITION OF VIEWPOINTS
DATA PLATE
1 2
3
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
1 - Type and model unit - modification index

2 - Serial number
3 - Lubricant

CONVERSION TABLES
CONVERSION TABLES
UNITS OF PRESSURE
Atm Bar MPa Pa PSI
Atm 1 1 0,1 105 14,4
Bar 1 1 0,1 105 14,4
MPa 10 10 1 106 144
Pa 0,00001 0,00001 10-6 1 -
PSI - - - - 1
UNIT OF WEIGHT
N daN kN kg lbs
1N 1 0,1 0,001 0,102 0,225
1daN 10 1 0,01 1,02 2,25
1kN 1000 100 1 102 225
1kg 9,81 0,981 0,00981 1 2,205
UNITS OF TORQUE
N·m daN·m kN·m kg·m lb·in
1N·m 1 0,1 0,001 0,102 8,854
1daN·m 10 1 0,01 1,02 88,54
1kN·m 1000 100 1 102 8854
1kg·m 9,81 0,981 0,00981 1 86,8
1 lb·in 0,1129 0,01129 0,0001129 0,01152 1

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
COARSE PITCH
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M6 x 1 mm 9,5 – 10,5 N·m 10,5 – 11,5 N·m 14,3 – 15,7 N·m 15,2 – 16,8 N·m 16,2 – 17,8 N·m 18,1 – 20 N·m
M8 x 1,25 mm 23,8 – 26,2 N·m 25,6 – 28,4 N·m 34,2 – 37,8 N·m 36,7 – 40,5 N·m 39 – 43 N·m 43,7 – 48,3 N·m
M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m
M14 x 2 mm 129 – 143 N·m 143 – 158 N·m 182 – 202 N·m 200 – 221 N·m 221 – 244 N·m 238 – 263 N·m
FINE PITCH
SIZE OF BOLT TYPE OF BOLT
8.8 8.8 + Loctite 270 10.9 10.9 + Loctite 270 12.9 12.9 + Loctite 270
M8 x 1 mm 25,7 – 28,3 N·m 27,5 – 30,5 N·m 36,2 – 39,8 N·m 40 – 44 N·m 42,8 – 47,2 N·m 47,5 – 52,5 N·m
M10 x 1,25 mm 49,4 – 54,6 N·m 55,2 – 61 N·m 71,5 – 78,5 N·m 78 – 86 N·m 86 – 94 N·m 93 – 103 N·m

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.
RECOMMENDED WHEEL NUTS TORQUE
CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY
ST 37 **ST 52
WHEEL NUTS WITH M18 x 1,5 mm 330 N·m 460 N·m

INTEGRATE
M20 x 1,5 mm 490 N·m 630 N·m
SPHERICAL COLLAR
M22 x 1,5 mm 630 N·m 740 N·m
FLAT COLLAR WHEEL M18 x 1,5 mm 270 N·m 360 N·m

NUTS WITH SEPARATE
M20 x 1,5 mm 360 N·m 450 N·m
SPHERICAL LOCK
WASHER M22 x 1,5 mm 460 N·m 550 N·m
WHEEL NUTS WITH IN- M18 x 1,5 mm 260 N·m 360 N·m
TEGRATE SEAT
M20 x 1,5 mm 350 N·m 500 N·m
CAPTIVE WASHER
M22 x 1,5 mm 450 N·m 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 & 10.9 STUD MATERIAL QUALITY 10.9 *ALLOW TIGHT TORQUE
M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m
M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m
M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m
*THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST BE RELATED ON STUD MATERIAL QUALITY
(DANA AXLES ARE 10.9 ONLY).

MAINTENANCE
MAINTENANCE POINTS
4 4
4
1 3 1 3
2 4 2 4 2
1 3
2
1 - Oil filling plug
2 - Oil draining plug
3 - Check level plug
4 - Check brake disc wear
Minimum thickness between counter discs is 5.2 mm.
NOTE:
For details see BRAKE WEAR CHECK PROCEDURE p. 51.

OIL DRAINING MANDATORY PROCEDURE
OIL DRAINING MANDATORY PROCEDURE
WARNING
• Do not attempt any maintenance if the axle is hot (40-50°C / 104-122°F). Hot oil and components can cause personal in-
jury. Avoid skin contact. Wear protective gloves and glasses.
• Make sure all fluids are contained during inspection, maintenance, tests, adjustment and repair of the product. Prepare a
suitable container to collect the fluid before removing any component containing fluids. Dispose of all fluids following legal
and local regulations.
CENTRAL HOUSING
Before draining oil it is mandatory to loosen the oil filling plug or the breather (if present), and wait until the internal pressure is
completely released. Remove the oil draining plug and drain oil only when the pressure is completely released.
PLANETARY GEAR REDUCTION

Before draining oil it is mandatory to rotate the planetary gear reduction in order to move the oil plug in filling position, then
loosen the oil plug and wait until the internal pressure is completely released. Remove the oil plug and drain oil only when the
pressure is completely released.

1ST CHANGE /
OPERATION COMPARTMENT FREQUENCY (whs) LUBRICANTS REMARKS
CHECK (whs)
Oil level check All 10 whs Monthly For details see below Clean carefully oil plug magnet
Central body standard bevel
gears - UTTO (API GL4), or
gear: J20/C, MF M1143, or If with limited slip differential, and/or
gear: SAE80W/90 (API GL4
ASM-0029E - 223 Axle Service Manual

Differential 100 - 250 whs max. * wet brakes, use LS additivated oils.
MAINTENANCE INTERVALS
or GL5) Clean carefully oil plug magnet.

Central body hypoid bevel
gears - SAE80W/90 (API GL5)
Oil Change 1000 whs UTTO (API GL4) J20/C; or
Hub Reduction 100 - 250 whs max. * gear: SAE80W/90 (API GL4 Clean carefully oil plug magnet.
or GL5)
Gears with wet discs clutch -
ATF GM Dexron IIE, Dexron III Clean carefully oil plug magnet.
Dropbox (if any) 100 - 250 whs max. * Only gears - UTTO J20/C, or * in accordance with Machine Service
gear: SAE80W/90 (API GL4 requirements
or GL5)
Negative brake (SAHR) For hydraulic actuations Not applicable

(brakes, SAHR, 100% diff.
Adjustment 100 whs Every 500 whs
lock, etc.) use ATF oil e.g. GM DOT brake fluids oils are NOT compat-
Service brake Dexron IIE, Dexron III ible w/std oils
Check for any damage or corrosion of
Tightening Wheel nuts 10 whs Every 200 whs No lubricant allowed
treads or mating surfaces
King Pin Tapered Bearings 10 whs Supply grease until clean grease is vis-
NLGI2 EP or NLGI3 EP ible from outside.
Seals 10 whs Normal work – Weekly
Grease performance level acc. to: Ac-
Greasing King Pin Bushings 10 whs or
cording to DIN 51825 level KP2K-30
Severe duty – Daily NLGI2 EP or NLGI3 EP with
(NLGI2) or KP3K-20 (NLGI3); ASTM
Trunnion Bushings 10 whs Moly Addittive
D4950 NLGI2 GC-LB
In case of severe duty, half oil change intervals must be applied.

In case of extreme enviroments, chatter noise, reduce oil change intervals accordingly.
In case of extremely low ambient temperatures (<-20°C), use appropriate oils w/ low viscosity: UTTO J20/D (std Bevel Gears), SAE 75W/90 API GL5 LS (Hypoid Bevel
Dana Holding Corporation

Gears: models 192, 193, 194).
API GL5: Acc. To MIL L-2105-B
MAINTENANCE INTERVALS
See PSB 00279 (latest update) for more info regarding lubricants and viscosity grades.
13
LUBRICANT & SEALANT SPECIFICATIONS

1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with
similar products marketed by different brand names with different trade marks.
LOCTITE 242
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it,
completely remove any lubricant by using the specific activator.
LOCTITE 243
The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
LOCTITE 270
Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubricant by using
the specific activator.
To remove parts, it may be necessary to heat them at 80° C approximately.
LOCTITE 275
Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for pipe sealing
and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum diametrical clearance of 0.25
mm.
LOCTITE 510
Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal clearances
between flanges up to 0.2 mm.
LOCTITE 577
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it, remove any
lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so heating may be necessary
for larger diameters.
LOCTITE 638
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with cle-
arance ranging between 0.1 and 0.25 mm.
LOCTITE 648
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (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 physical elements.
Polymerises with non-corrosive dampness.
TECNO LUBE/101 (SILICONE-BASED GREASE)
Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
MOLIKOTE (DOW CORNING)
Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sticking and oxi-
dation of parts that are not lubricated on a regular basis.
(LITHIUM-BASED) GREASE
Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.

SAFETY PRECAUTIONS
1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly po-
sitioned and that the machine is locked lengthways.
4 - Do not admit any other person inside 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 - During maintenance operations, always wear protective glasses, safety footwear, protective gloves and all
P.P.E. (Personal Protective Equipment) in function of the risks which the workers may be exposed to.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste
and dispose of them according to the relative law provisions obtaining in the country where the axles are being
overhauled.
9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol,
xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment
friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some
of the diagrams.
11 - After repair work has been completed, accurately touch up any coated part that may have been damaged.
12 - Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.
13 - Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE
p. 12.
Indicates an imminently hazardous situation

DANGER which, if not avoided, will result in death or se-
rious injury.
Indicates an imminently hazardous situation
WARNING which, if not avoided, could result in death or se-
rious injury.
Indicates a situation which, if not avoided, may
CAUTION result in damage to components.
Indicates information which may make product

NOTICE service easier to perform.


PLANETARY REDUCTION GEAR
EXPLODED VIEW
15
16
7
8
11
9
12 10
14
4
13
2
1
6
5
17
18 3
19

DISASSEMBLY
DISASSEMBLY
CAUTION 4
Before draining oil, release the internal pressure, for details
see OIL DRAINING MANDATORY PROCEDURE p. 12.
1
5
FIGURE 4: Loosen and remove the nuts (4) that lock the gear
safety flange (5).
6
FIGURE 1: Remove check screws (1) from planetary cover.
3 FIGURE 5: Remove safety flange (6).
2
5
FIGURE 2: Alternately insert a lever in the slots provided and

pry to separate the planetary cover (2) from the steering case
(3).
FIGURE 6: Remove the complete ring gear flange (5) by using

a puller and applying counter pressure to the studs.
FIGURE 3: Remove the complete planetary cover (2).

DISASSEMBLY
7
3
FIGURE 7: Partially extract the wheel hub (7) by using a pla- FIGURE 10: Take out the pins and remove the steering case
stic hammer. (3).
For pin removal details, see PLANETARY REDUCTION GEAR
NOTE: p. 17.
Hammer alternately on several equidistant points.
8
FIGURE 11: Remove the snap rings (9).
FIGURE 8: Remove the external bearing (8).
10
7
FIGURE 12: Using a puller, remove the planetary gears (10).
FIGURE 9: Draw out the wheel hub (7).
NOTE:
Write down direction of installation of planetary gears.

DISASSEMBLY
16
12 13
FIGURE 13: Remove the ring gear (13) snap ring (12). FIGURE 16: Remove inner bearing (16).
14
8
7
FIGURE 17: Remove the outer thrust blocks of bearings (8)

FIGURE 14: Remove ring gear flange (14). (16) by driving a pin driver in the slots provided on the hub (7).
NOTE:
Hammer alternately to avoid thrust block clamping and
15 deformation.
17
17
15
FIGURE 15: Remove seal ring (15) from wheel hub (7).
NOTE:
Mark the seal ring position.
FIGURE 18: Using a puller, remove seal ring (17) from stee-
ring case (3).
NOTE:
Write down seal ring orientation.

DISASSEMBLY
T1
18
FIGURE 19: Using driver T1 (See drawing T1 p. 26), extract

the guide bushing (18) of twin u-joint.
Only if necessary, remove any damaged studs (19), which
need to be replaced.

ASSEMBLY
ASSEMBLY
16 15
15
T2
16
18
FIGURE 23: Install bearing (16).

Apply Arexons seal rubber cement to the outer surface of seal
FIGURE 20: Fit the bushing (18) in the steering case (3) using ring (15).
tool T2 (See drawing T2 p. 26). Position the seal ring (15) in the hub (7).
CAUTION
17
T3 Check ring orientation carefully.
15
17
T5
15
FIGURE 21: Apply a coat of AREXONS rubber cement to the
outer metal surface of the snap ring (17).
Position the seal ring and, using tool T3 (See drawing T3
p. 27), fit it in the appropriate seat.
FIGURE 24: Position tool T5 (See drawing T5 p. 29) and press

CAUTION the seal ring (15) into its seat.
Check direction of installation carefully.
7
7
T4 8
16
T4
7
7
FIGURE 25: Turn the hub over (7), lubricate bearing seat and,
FIGURE 22: Position the wheel hub (7) under a press; lubri-
using tool T4 (See drawing T4 p. 28) install the bearing thrust
cate the outer seat of bearing and, using tool T4 (See drawing
block (8).
T4 p. 28), install the thrust block of bearing (16).

ASSEMBLY
14
12 9
10
13
FIGURE 26: Fit the flange (14) in the ring gear (13) and lock FIGURE 28: Lock gears (10) into position by installing the
into position with snap ring (12). snap rings (9).
NOTE:
Check that snap ring (12) is fully inserted in the slot of ring
gear (13).
3
T6
2
10
9
FIGURE 29: Oil the seal ring and bushing. Slip the steering
2 case (3) onto the twin u-joint and fit the pivot pins and con-
nect the steering bar.
10 For details, see PLANETARY REDUCTION GEAR p. 17.
FIGURE 27: Mount gears (10) onto the pins of the planetary
cover (2).
To insert gears, use tool T6 (See drawing T6 p. 29).
Loctite 270 Tecnolube 101

CAUTION
The radiused part of bearings' inner ring must face the bot-
tom of the pin.
FIGURE 30: Only if studs have been removed. Apply a coat

of Loctite 270 to the fast end of studs (19) and apply Tecno-
lube 101 to ground nut end; tighten studs (19) as far as they
will go.

ASSEMBLY
FIGURE 31: Install the wheel hub (7) onto the steering case FIGURE 34: Ensure that faces are thoroughly cleaned, and
(3). then mount the safety flange (6).
FIGURE 32: Install the outer bearing (8). FIGURE 35: Apply Loctite 242 to the studs and tighten nuts
(4).
NOTE: Tighten nuts (4) in two stages using the criss-cross method.
Initial tightening torque: 250 N·m.
Push the bearing as far as it will go by tapping with a pla-
Final tightening torque: 460 - 465 N·m.
stic hammer all around the rim.
2
5
FIGURE 36: Fit the planetary cover (2) on the wheel hub (7).
FIGURE 33: Install the complete ring gear flange (5).
NOTE:
To engage the flange (5), use a plastic hammer and ham-
CAUTION
mer alternately on several equidistant points. Check state and position of o-ring (11).

ASSEMBLY
2 1
FIGURE 37: Lock the planetary cover (2) with screws (1).
Tightening torque for screws: 40 - 50 N·m.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2364
260
25 27 205
30
45
Ø61. 8
Ø2 5
Ø5 9
Ø4 6
R7 120 3 x45°
.5
2 x 45 °
2 x 45 °
R1.5
T2
P/N: 3348
35
0. 8
120 30
Ø6 5 ---- 0.0. 64
Ø6 0 ---- 0.08
0.12
Ø2 5
Ø7 5
Ø4 5
R1
0
0. 8
3 x15°
0. 8
1. 5 0
-- 0. 2 3 x15°
40 200
250

SPECIAL TOOLS
T3
P/N: 2365
32 32
0
R1
120 30
-- 0. 1
-- 0. 2
-- 0. 2
+0
Ø7 4 ---- 0.0. 64
Ø60. 3
Ø58. 5
Ø2 5
Ø9 0
3x15 °
3x15 °
32
6 3. 5 +-- 0,0 2
21 14 215
250
D1240330

SPECIAL TOOLS
T4
P/N: 3265
Ø184
Ø4 0 Ø3 5
12. 5
25
45
32
0
R1
20°
176
131
5x15 °
32
-- 0. 1
Ø5 0 -- 0. 3
Ø178 27. 5
20°
Ø4 5
0. 8
0. 8
0. 8
20
60
5x15 °
47.631
126
166
0. 8
Ø50 H7
141
R3
Ø60 H7-p 6
0. 8
Ø165
0. 8
Ø184
± 0.03
Ø200

SPECIAL TOOLS
T5
P/N: 2366
Ø180
Ø4 0
30
140
90
0
R1
0. 8
R3
15
10
48
0. 8
28
14
0. 8
6. 5
0. 8 Ø140
0. 8
+ 0. 1
Ø154 -- 0. 2
Ø178
Ø189
Ø205
T6
P/N: 2378
2 x15 ° 0.8
R3 100 30
Ø51
Ø59
Ø30
3 x45 °
10 15
25
0.8
175

SPECIAL TOOLS

COMPLETE STEERING CASE
EXPLODED VIEW
8 5
9
3
10
2
18
12 13
10
14
15
16
17

DISASSEMBLY
DISASSEMBLY
CAUTION
Before draining oil, release the internal pressure, for details 4
3
FIGURE 3: Using two levers, remove the top articulation pin
(4) complete with front seal (9) and shims (3) .
8 Pay attention not to damage the surfaces.
15
1
FIGURE 1: Loosen and remove the capscrews (15, 8) from
the articulation pin (19, 4).
10
FIGURE 4: Remove the complete steering case (1).
19
FIGURE 2: Remove the bottom articulation (19) pin complete
with front sealing ring (10).
3
19
4
upper articulation pin under articulation pin

ASSEMBLY
ASSEMBLY
FIGURE 8: Lubricate the unit and the steering case.

1
FIGURE 5: Lubricate the terminal of the u-joint and install the
steering case (1).
Pay attention not to damage the dust cover rings and the se- 12
aling rings.
10
0,85 mm 4
1
19
under articulation pin
FIGURE 9: Fit the unit (19) in the steering case (1). Position
the screws (15) and tighten securely.
Check for the correct assembly side of the seal (10).
3
FIGURE 6: Prepare a series of shims (3) of 0,85 mm to be as-
sembled under the upper pin (4).
140 N·m
3 15
140 N·m
4
upper articulation pin FIGURE 10: Tighten the new capscrews (15) of the top and
bottom articulation pins in sequence using the criss-cross
method.
Torque wrench setting: 140 N·m
FIGURE 7: Fit a new seal (3) onto the top articulation pin (4).
Lubricate and install the unit in the steering case.
Position the screws (8) and tighten to 140 N·m.
Check the correct assembly side of the seal (3).

ASSEMBLY
FIGURE 11: Using a lever, check that there is no vertical gap.
30 - 60 N·m
FIGURE 12: Check the torque of the pins, which has to be

between 30 and 60 N·m.
If the preliminary measured value is too high, the shims have
to be increased.

STEERING CYLINDER
EXPLODED VIEW
10
11
12 A
12
2 8
6
12 A
7
12
11
1 4
13
16
3 14
9 17
15
14
2
12
11
10
7 9
2
1
4
6

DISASSEMBLY
DISASSEMBLY
CAUTION
Before draining oil, release the internal pressure, for details 3
see OIL DRAINING MANDATORY PROCEDURE p. 12. 5
FIGURE 3: Using a puller, disconnect the tapered pins of the

joints (3) from the steering cases (5).
FIGURE 1: If required, remove the steering piston stroke cen-

tering sensor (1).
3 4
FIGURE 4: Disconnect left and right steering bars from piston
2 (6).
CAUTION
To ease bar removal, heat the threaded portion of the piston
to approximately 212 °F [100 °C] with a heat gun.
FIGURE 2: Loosen the check nuts (2) on the joints (3) of the
steering bars (4). Remove nuts.
8
NOTE: 7
Should the joint rotate, hold it with a wrench inserted in
the seat provided.
CAUTION
The self-locking nuts (2) must be replaced once every 5 di-
sassemblies.
FIGURE 5: Loosen and remove the steering cylinder (8)

screws (7).

DISASSEMBLY
8
T1
3
5
FIGURE 6: Extract the steering cylinder (8) using a plastic FIGURE 9: Using a punch, force the stop ring (4) located in-
hammer. side the cylinder (3) and extract ring using a screwdriver.
12
12 10
10 99
11
11 55
FIGURE 7: Before attempting to disassemble the unit, drain FIGURE 10: Using a plastic hammer, hammer the piston (5)
the oil in the cylinder chambers completely. so it strikes against the head (2).
Using a screwdriver, remove the snap ring (1) of the cylinder Continue until the head (2) is ejected from the cylinder (3).
head (2).
12
12 10
10 99 T1
11
11 55
5
FIGURE 11: Take the cylinder unit (3) apart by extracting the
FIGURE 8: Lightly tap the cylinder head (2) with a plastic head (2) first, followed by the piston (5).
hammer to push it inside the cylinder (3).
NOTE: CAUTION
Insert the cylinder head so it is flush with the cylinder.
Write down direction of installation of piston whose seal ring
"A" is oriented towards cylinder head (2).

DISASSEMBLY
3
2
FIGURE 12: Remove all seals, anti-extrusion rings, and scra-

per rings from head (2), cylinder (3) and piston (5).
NOTE:
1 - All seals must be replaced at each disassembly.
2 - Pay particular attention not to damage seal seats and
piston beds.

ASSEMBLY
ASSEMBLY
T1
3
5
3 FIGURE 16: Apply tool T1 (See drawing T1 p. 45) to the pi-

ston rod on non-head side (2) and center rod into cylinder (3)
FIGURE 13: Grease and install the piston rod seal ring (6) and so as to fit it into piston (5).
scraper ring (7) into cylinder (3).
NOTE:
Lightly grease seals and cylinder.
5
FIGURE 14: Grease and install the piston rod seal ring (6) and
scraper ring (7) into the head (2).
FIGURE 17: Introduce the piston (5) into the cylinder by ap-
proximately 150 mm using a plastic hammer.
2
T1
FIGURE 15: Prepare piston (5) by fitting it with guide ring (9), 5
magnetic ring (10), o-ring (11), and seal (12).
CAUTION FIGURE 18: Remove tool T1 (See drawing T1 p. 45) and ap-
ply it to the opposite side of the piston (5).
1 - To ease installation, lubricate with grease.
2 - If a centering sensor is not required, the magnetic ring
(10) can be replaced with an additional guide ring (9).

ASSEMBLY
3 2
2
FIGURE 19: Grease the seals of the head (2), slip the head FIGURE 22: Fit the snap ring (1) of head (2).
onto the piston and, using a plastic hammer, introduce head If necessary, force it into the seat with a punch and hammer.
into cylinder (3).
NOTE: CAUTION
Introduce the head so it is flush with the cylinder.
Make sure that the snap ring (1) fits snugly in its seat.
8
3
FIGURE 20: Introduce the stop ring (4) and ensure that it sets
FIGURE 23: Check the condition of the axle unit's o-rings (9).
in the seat of cylinder (3).
Grease piston seats with Tecnolube Seal 101 and install
cylinder using a plastic hammer.
7 8
4
FIGURE 21: Using two screwdrivers or levers, force the head

until it is seated against the stop ring (4). FIGURE 24: Block cylinder (8) with screws (7) coated with
Loctite 242 and tightened to a torque of 180 - 200 N·m.

ASSEMBLY
19
FIGURE 25: Apply Loctite to the threaded portion of the ste- FIGURE 27: If required, install the steering piston stroke cen-
ering bars and connect the bars by tightening the ends in the tering sensor (1) for checking piston centering and tighten
piston rod. screws (13). Tightening torque: 5 - 6 N·m
Tightening torque: 430 - 470 N·m.
CAUTION
CAUTION
If required, eliminate the action of the negative brake.
Accurately remove grease from the threads using an activa-
tor before applying the thread locking compound.
3 B
B
T2
5
2
FIGURE 28: Apply tools T2 (See drawing T2 p. 45) onto the

wheel hubs and lock tools.
FIGURE 26: Introduce the pins (3) in the steering cases (5) Check that tools are perfectly flat and parallel to each other
and lock into position with nuts (2) tightened to a torque of using a level "B".
350 - 390 N·m.
FIGURE 29: Connect the sensor (1) to the control device ac-
cording to either of the following diagrams.

ASSEMBLY
I max=0,80 A
NERO
BLACK C
CONNETTORE
CONNECTOR
2 BLU
1 3
BLUE
--
4
BATTERIA
BATTERY
MARRONE
BROWN
+
2A
FIGURE 30: Sensor wiring diagram for STANDARD version. FIGURE 33: Check distance "C" of piston on either of the two
sides and write down distance dimension to check subse-
I max=0,80 A quent adjustments.
NERO
BLACK NOTE:
CONNETOR For cylinders without sensors, piston must be centered
CONNECTOR BATTERIA based on maximum stroke.
2 BATTERY
BLU
1 3
BLUE
--
4
LL
MARRONE
BROWN
+ LL
2A
FIGURE 31: Sensor wiring diagram for OPTIONAL version.
== =
= T2
T2
FIGURE 34: Lay level "L" on two upper studs and line them
up. Apply tools T2 (See drawing T2 p. 45) to the two horizon-
tal studs; hold them in position with two nuts, level them, and
finally lock into position.
T2
FIGURE 32: Center by slowly moving the piston first in one
direction, then in the opposite one, position the piston in the
middle point of the stroke, which is determined by the control
device signalling lamp turning on and switching off in the re-
verse stage.
T2 T2
FIGURE 35: Without moving the piston, check front “B” and
rear “A” using tool T1 (See drawing T2 p. 45) at “R” value.
R = 400 mm (see picture below).

ASSEMBLY
A
12
11
R
R
B
FIGURE 36: Adjust the convergence with a difference betwe- FIGURE 39: Once toe-in has been adjusted, lock nuts (11).
en “A” and “B” of maximum 2,5 mm. Tightening torque for nuts: 328 - 363 N·m.
A ± B = 2,5 mm
R = 400 mm
Pos. 2 Pos. 4
12
11
Pos. 3 Pos. 1
STEERING CYLINDER
CILINDRO STERZO
LENKZYLINDER
CILINDRO DE DESVIO
CYLINDRE DE DIRECTION
FIGURE 40: ADJUSTING THE STEERING ANGLE

Loosen the nut of one of the adjusting screws on cylinder si-
FIGURE 37: TOE-IN de.
If necessary, adjust alignment after loosening the check nuts
(11) of ball pins (12). NOTE:
Perform the same operations on both sides (see dia-
gram).
12
12A
FIGURE 38: Hold joints (12A) tight and rotate the ball pins (12) 15 14
until tools T2 (See drawing T2 p. 45) become parallel to each
other. FIGURE 41: Adjust the jutting portion of the screw (15) accor-
ding to data shown in the table.
NOTE: Lock into position with nut (14) tightened to 145 - 148 N·m.
1 - Loosen the nuts by a few turns.
2 - Half a turn of the pin will reduce the front stud by about
3 mm and increase the rear one by about 3 mm.

ASSEMBLY
15
14
FIGURE 42: Perform one full steering operation until the adju-
sted screw (15) leans against the arm stop.
16
17
14
FIGURE 43: While holding the adjustment screw in position
against the arm stop, adjust the screw opposite (16), on non-
cylinder side, until it leans against the arm stop.
CAUTION
The screws (15) and (16) must lean against the respective
arm stops all at the same time.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2368
Ø5 0 ---- 0.05
0.10
0. 4
M8 x1.2 5
R2 5°
.5
15
30
44
14
75
6
7
1
1 x45
28 °
Ø6.5
0
Ø28. 3 -- 0.05
Ø48. 1 + 0.05
0
T2
P/N: 2367
5
R1
23
R 11 0
100
50
5 x45°
22 40
55 500
555
17 ±0. 1
63
125
125

SPECIAL TOOLS

U-JOINT
EXPLODED VIEW
4
6
7
9
5
8
3
2

DISASSEMBLY
DISASSEMBLY
CAUTION
4
2 5
1
FIGURE 3: Remove the snap ring (4) of the bushing kit (5).
FIGURE 1: Loosen and remove the check nut (1) of the stud 5
(2). Remove stud (2).
FIGURE 4: Place the u-joint under a press and remove the

complete bushing (5).
FIGURE 2: Extract the whole twin u-joint (3).

6
NOTE:
7
If necessary, use a plastic hammer or lever to ease ex-
traction of the twin u-joint. 8
FIGURE 5: Remove the bearing (7) snap ring (6).

Remove the o-ring (8) and, using a puller for inner parts, re-
move the bearing (7) and seal ring (9).
NOTE:
Write down direction of installation of seal ring.

ASSEMBLY
ASSEMBLY
T1 T2
4
5 5
FIGURE 9: Install the bushing (5) snap ring (4); position the o-
FIGURE 6: Using tools T1 (See drawing T1 p. 50) and T2 (See ring (8) as well.
drawing T2 p. 50), introduce the seal ring (9) and bearing (7)
into the bushing (5).
NOTE:
Check direction of installation of seal (9) carefully. 2
6
7
FIGURE 10: Introduce the twin U-joint (3) into the arm and
lock into position with stud (2) coated with Loctite 242.
Tighten stud to a maximum torque of 15 N·m.
FIGURE 7: Install the bearing (7) snap ring (6). 1

1 22
1 2
FIGURE 11: Apply Loctite 242 to the jutting portion of the

stud (2) and tighten nut (1).
Tighten nut (1) to a torque of 60 - 70 N·m while holding stud
FIGURE 8: Install the complete bushing (5) onto the twin u-
(2) in position.
joint and set bushing into position with a plastic hammer.
CAUTION
Tap around the whole rim.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 3342
100 30
0.8 0.8
0. 8
Ø54, 5 -- 0.0 1
Ø9 0 -- 0.15
Ø5 4 + 0.0 1
Ø7 9
Ø3 0
3 x45°
R1
0. 8
3 x15°
0. 8
7
2,5 -- 0.0 2
14 10 120
T2
P/N: 2301
10
1. 5 x45°
R1
0. 8
100 30
49. 5
Ø3 0
89
3 x45°
R1
0
0. 8
130
155

BRAKE WEAR CHECK PROCEDURE
OLD VERSION
CAUTION
Perform all operations on both arms.
FIGURE 1: Remove the oil drain plug and discharge oil.
T1
FIGURE 2: Apply the parking brake (or have someone hold

the service brake) and with either brake applied, check the di-
stance between discs using tool T1 (See drawing T1 p. 54).
Minimum distance: 5,2 mm
CAUTION
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE AND NEGA-
TIVE PARKING BRAKE p. 55.

SPECIAL TOOLS
FIGURE 3: Checking brake distance with the T1 go / no-go

gauge.
35 - 50 N·m
FIGURE 4: Install the oil drain plug.
Torque wrench setting for screws: 35 - 50 N·m.
Fill with oil.

SPECIAL TOOLS
NEW VERSION
CAUTION
Perform all operations on both arms.
35 - 50 N·m
FIGURE 4: Install the inspection plug.
Torque wrench setting for screws: 35 - 50 N·m.
FIGURE 1: Remove the inspection plug.
T1
FIGURE 2: Apply the parking brake (or have someone hold

the service brake) and with either brake applied, check the di-
stance between discs using tool T1 (See drawing T1 p. 54).
Minimum distance: 5,2 mm
CAUTION
Replace the braking disks and the intermediate disks on
both sides if necessary. See SERVICE BRAKE AND NEGA-
TIVE PARKING BRAKE p. 55.
FIGURE 3: Checking brake distance with the T1 go / no-go

gauge.

SPECIAL TOOLS
SPECIAL TOOLS
T1
5.2
°
45
1
25
32
32
160
110
8
32
32
25
1
°
45
10
5.4

SERVICE BRAKE AND NEGATIVE PARKING BRAKE
EXPLODED VIEW
1
2
3 6
5
7
4
26 8
9 10
11
25
12
13
24
14
15
23
17 16
18
27 22 19
21
20
28
29
30
31

DISASSEMBLY
DISASSEMBLY
DANGER
31
31
Before maintaining brakes, when the axle is installed on the
vehicle, follow all safety instructions in the Original Equip-
ment Manufacturer (OEM) manual that came with the vehi-
cle.
CAUTION
FIGURE 2: Sling the arm to be removed and connect it to a
hoist.
21-35 Bar Loosen and remove screws (31).
FIGURE 1: Connect an external pump to the union piece “P1“

of the negative brake and introduce a pressure of 21 - 35 bar
to eliminate the pressure of the Belleville washers (1).
FIGURE 3: Remove arm together with brakes and axle shafts;
lay down the arm vertically.
DANGER
Always check that the hydraulic circuit test for leaks under
pressure. Always use a cardboard or a panel to control the
loss.
A leak from a hole of the size of a pin can cause serious in-
jury. If fluid is injected into the skin it is necessary to seek
immediate medical care.

DISASSEMBLY
13
13
0 bar
12
12
13
13
FIGURE 4: Gradually release the pressure in the braking cir- FIGURE 6: Remove the adjusting screws (13) from the
cuit, bringing it to zero through the external pump. counterwasher (23).
DANGER
Do not remove any part of the hydraulic circuit without ha-
ving completely released the hydraulic pressure.
The removal of pressurized parts or loss caused from relea-
sing these components can cause serious injuries and even
death. A leak from a hole of the size of a pin can cause se-
rious injury. If fluid is injected into the skin it is necessary to
seek immediate medical care.
21
FIGURE 7: Remove the pin screws (21).
23
23
FIGURE 5: Gradually loosen the sleeve and remove.
DANGER Down
FIGURE 8: Write down their order of assembly and remove
Carefully check that the hydraulic pressure is discharged the counterwasher (23).
completely before removing the external pump sleeve con-
nected to the brake.

DISASSEMBLY
1
1
FIGURE 12: Remove the Belleville washers (1).

FIGURE 9: Loosen the studs in an alternate method and re-
move them.
NOTE:
Check the sense of direction of washers (1).
24
24
FIGURE 10: Remove the cylinder (24).

FIGURE 13: The o-rings (2) must be replaced each time the
unit is disassembled.
11
26
26
Service Brake
FIGURE 11: Remove the centering device (26 ) in the cylinder.
FIGURE 14: Slowly introduce low-pressure compressed air

through the connection member for the service brake (P2), in
order to extract the piston (11).
CAUTION
Hold the piston (11) back, as it may be suddenly ejected and
damaged.

DISASSEMBLY
24
16
FIGURE 15: Mark the assembly position.

FIGURE 18: Remove the flange (17) complete with the discs
( 20 , 19, 18) .
14
3 Down 15
17 16
18
19
20

CAUTION 27
27

damaged.
14
15
28
28
FIGURE 19: Remove spacer-braking discs (27) and shims

(28), noting down direction of assembly.
NOTE:
Build a stack of washers and check the measurement.
16
16
FIGURE 17: Remove braking discs (14, 15, 16), noting down
direction of assembly.
NOTE:
If disks are not being replaced, avoid changing their position.

ASSEMBLY
ASSEMBLY
11
11
24
24
CAUTION
The o-rings always have to be assembled from the pressure
facing side.
Down
FIGURE 22: Fit o-ring (9) and anti-extrusion ring (10) onto the
piston (11).
Lubricate the piston and the o-rings and install the unit into
the cylinder (24).
23
23 Down
FIGURE 20: Check the position of the anti-extrusion (4) and 11

11
o-rings (2, 25). Out Side
Lubricate the piston and the o-rings and install the unit (3) into
the cylinder (24).
10
10
9
9
3
FIGURE 23: The o-rings always have to be assembled from
the pressure facing side.
FIGURE 21: Using a plastic hammer, install the piston (3) into 11
11
the cylinder (24).
NOTE:
Lightly hammer all around the edge in an alternate se-
quence.
24
24
FIGURE 24: Using a plastic hammer, install the piston (11)

into the cylinder (24).
NOTE:
quence.

ASSEMBLY
24
24
1
DOWN
24
24
FIGURE 25: Position the Belleville washers (1) and engage FIGURE 28: Engage the cylinder (24).
the cylinder (24).
NOTE:
NOTE: Check the sense of direction of washers (1) and relative
Check the sense of direction of Belleville washers (1) and centering.
relative centering.
Loctite 242
26
26
FIGURE 29: Insert the screws and tighten them alternately.

FIGURE 26: Install the centering device (26) in the cylinder. Lock the cylinder.
30-35 N·m
2
FIGURE 27: Check integrity and position of the cylinder's o- FIGURE 30: Tightening the studs to a torque of 30 - 35 N·m.
ring (2).

ASSEMBLY
23
23
21-35 Bar
FIGURE 31: Connect an external pump to the negative brake FIGURE 33: Insert the intermediate disk (23).
and introduce pressure to 21 -35 bar.
12
12
DANGER
Always check that the hydraulic circuit test for leaks under
pressure. Always use a cardboard or a panel to control the 13
13
loss.
A leak from a hole of the size of a pin can cause serious in-
jury. If fluid is injected into the skin it is necessary to seek
immediate medical care.
23
23
FIGURE 34: Fit the reversal springs (12, 13) on the interme-
diate disk (23).
Negative Brake
10-15 N·m
Service Brake Drilock
22
22
FIGURE 35: Tighten with torque wrench setting of 10 - 15

N·m
CAUTION
23
23 Use only new screws pre-treated with Driloc locking adhe-
sive. Threads must be cleaned from oil. Degrease only non
pre-treated threads.
FIGURE 32: Insert the stroke automatic regulation springs
(22); place them in line with the piston (23).

ASSEMBLY
1000Kg
Y V
Y 21
V
Y = BRAKE GAP
FIGURE 36: Y=brake gap FIGURE 39: Put the brake disc pack including the shim under
0,75mm 1,00mm 1,25mm 1,50mm a press, load with 1000 kg and take the measure “V”.
depending on axle configuration. EXAMPLE: V = 42,33 mm
5 - 7 N·m
Drilock
74 mm
Arm ﬁx quote = 74 mm
FIGURE 37: Fit the pin screws. FIGURE 40: Arm fix quote = 74 mm
Torque wrench setting: 5-7 N·m.
Y=brake gap
CAUTION
S 28
Use only new screws pre-treated with Driloc locking adhe-
sive. Threads must be cleaned from oil. Degrease only non
pre-treated threads.
X
S = 74mm - (x + y + v)
FIGURE 41: S = 74 mm - ( x + y + v ) = Thickness of shims to
insert under the shim washer.
EXAMPLE: 74 mm -(29 + 42,33 + 1,25) = S = 1,42 mm
X
X
FIGURE 38: Take the measurement from the surface of the

intermediate disk to the cover sealing surface with 30 bar of
pressure introduced.
EXAMPLE: 29 mm

ASSEMBLY
18
18 20
20
19
19
S 28
17
17
20
20
3° Disc
18
18
FIGURE 42: Insert under the shim washer a thickness of FIGURE 45: Install the friction disc (18) on the flange (17) from
shims (28). arm side and insert the group on the u-joint.
18
18
16
16
First Disc
4° Disc
18
18
16
16
FIGURE 43: Install the friction disc (18) on the flange (17) from
arm side. FIGURE 46: Insert on the flange the discs (16, 15, 14).
19
19
2° Disc
19
19
FIGURE 44: Install the metal disc (19 ) on the flange (17) from
arm side. FIGURE 47: Check the alignment of last disc (14) and flange
(17).

ASSEMBLY
Loctite 242 / 30 - 35 N·m
Loctite 242 / 200 - 221 N·m

FIGURE 48: Apply Loctite 242 to the studs and tighten to 30 FIGURE 51: Tighten the nuts in two stages to 200 - 221 N·m.
- 35 N·m
0 bar
FIGURE 52: Gradually release the pressure in the braking cir-

FIGURE 49: Check integrity and position of the cylinder's o- cuit, bringing it to zero through the external pump.
ring.
DANGER
Do not remove any part of the hydraulic circuit without ha-
ving completely released the hydraulic pressure.
The removal of pressurized parts or loss caused from relea-
sing these components can cause serious injuries and even
death. A leak from a hole of the size of a pin can cause se-
rious injury. If fluid is injected into the skin it is necessary to
seek immediate medical care.
FIGURE 50: Check integrity and position of the arm's o-ring;

install the complete arm.
NOTE:
To assist axle shaft centering, slightly move the wheel
hub.

ASSEMBLY
FIGURE 53: Gradually loosen the sleeve and remove.
DANGER
Carefully check that the hydraulic pressure is discharged
completely before removing the external pump sleeve con-
nected to the brake.

RELEASE
RELEASE ADJUST
Tecno Lube 101
29
30
31
FIGURE 57: Remove screws complete with nuts and seals.

FIGURE 54: Loosen nuts (30) of screws (31) provided for the Replace seals, apply silicone-based Tecno Lube /101 grease
mechanical and manual release of the braking units, then to the screws and install all parts into the arm.
move the nuts backwards by approximately 8 mm.
34 mm
FIGURE 55: Tighten screws (31) to fasten them onto the pres- FIGURE 58: Adjust screws (31) to obtain a distance of 34 ± 0.5
sure plate (23). mm between axle machined surface and screw underhead.
30 31
FIGURE 56: Using a wrench, tighten the screws (31) in an al-

ternate sequence by 1/4 turn at a time so as to compress the FIGURE 59: Lock into position with nuts (30).
Belleville washers and disengage the braking disks.
CAUTION
CAUTION Hold screws (31) into position while locking the nuts (30); af-
Tighten maximum by one turn. ter locking, check the distance of screws (31) once more.

ADJUST

DIFFERENTIAL UNIT
EXPLODED VIEW
1 2
3 4
7
42 8 9
5 10
19
39 6 17 20
18
38
22
12
40 24
13
14
28 29 30 15 21
41
23 27
37
25 26
31
32
33
34
36
35

DISASSEMBLY
DISASSEMBLY
CAUTION 2 26
T1
FIGURE 4: Only if removing or adjusting, use special tool T1

(See drawing T1 p. 79) to mark the position of the ring nuts (2)
and (26).

hoist. Loosen and remove screws and nuts.
FIGURE 5: Loosen the stud bolts (35, 41) and remove two of
them.
FIGURE 2: Only if removing or adjusting, remove the screw

(27).
80C°
38 33
FIGURE 6: Disjoin the cover (38, 33) crown side.
FIGURE 3: Only if removing or adjusting, uniformly heat the

ring nuts up to a temperature of 176 °F [80 °C].

DISASSEMBLY
29
FIGURE 7: Remove the cover and studs. FIGURE 10: Remove the cap (29).
3 25
37 36
33 38
FIGURE 8: Extract the whole differential unit. FIGURE 11: If the bearings need replacing, extract the exter-
nal thrust blocks of the bearings (3) and (25) from middle co-
ver (33, 38).
NOTE:
30 Accurately check the o-ring (37, 36).
3
FIGURE 9: Remove the snap ring (30).
FIGURE 12: If the bearing needs replacing, extract the bea-

ring (3).

DISASSEMBLY
24
25
23
FIGURE 13: If the bearing need replacing, extract the bearing FIGURE 16: Remove the screws (24) joining the differential
(25) from the differential carrier (23). unit half box.
4
23
FIGURE 14: Remove the ring gear (6) capscrews (4). FIGURE 17: Using a plastic hammer, take the half box (23, 5)
to pieces.
NOTE:
42
Write down the coupling marks.
23
FIGURE 15: Remove the spacer (42) and the ring gear (6).
FIGURE 18: Remove the upper half box (23).

DISASSEMBLY
22
8
21
FIGURE 19: Remove shoulder (22) and first planetary gear FIGURE 22: Remove the 2nd planetary gear (8) and shoulder
(21). ring (7).
15 19 18 23 5
14 20 P
SR
Sw
Sh
S
FIGURE 20: Remove shafts (18), complete with planetary ge- FIGURE 23: The differential unit.
ars (15, 19) and spherical shoulder washers (14, 20).
Sh = Shafts (18)(17)
9 13 17 SW = spherical shoulder washers (9)(13)(14)(20)

P = planetary gears (8)(21)
SR = shoulder ring (22)(7)
10 12 S = planet wheels (10)(12)(15)(19)
23 = upper half box
5 = half box crown side
FIGURE 21: Remove shafts (17), complete with planetary ge-

ars (10, 12) and spherical shoulder washers (9, 13).

ASSEMBLY
ASSEMBLY
22
8
21
5 FIGURE 27: Install the planetary gear (21) and shoulder ring
(22).
FIGURE 24: Install the shoulder ring (7) and planetary gear (8)
into the halfbox (5).
23
9 13 17
10 12
FIGURE 28: Mount the locking half-box (5) onto the half-box
(23)
FIGURE 25: Install the planetary gears (10, 12) and spherical
shoulder washers (9, 13) onto the shafts (17).
Install the planetary set. Loctite 270
15 19 18
24
14 20
FIGURE 29: Lock the half box with screws (24) coated with
Loctite 270.
FIGURE 26: Install the planetary gears (15, 19) and spherical
shoulder washers (14, 20) onto the shafts (18). CAUTION
Install the planetary set.
1 - The match marks on the two half-boxes must corre-
spond.
2 - Use only new screws.

ASSEMBLY
80 N·m 150 N·m
24
FIGURE 30: Fit the complete differential unit in a vice and FIGURE 33: Lock the ring gear (6) by tightening the screws (4)
tighten the screws (24) holding the two half boxes together to to a torque of 150 N·m using the criss-cross method.
a torque of 80 N·m.
CAUTION
100°
Tighten screws using the criss-cross method.
42 3
FIGURE 34: INSTALLATION OF THE DIFFERENTIAL UNIT

Position the differential unit under a press and, using a driver
6 with an adequate diameter, install the first bearing (3).
FIGURE 31: Install the spacer (42) and the ring gear (6).
100°
Loctite 270
25
FIGURE 35: Turn the unit upside down and install the second
bearing (25).
FIGURE 32: Mount the ring gear (6) and fasten it to the diffe-
rential box with screws (4).
CAUTION
Pay particular attention; position a shim with adequate dia-
CAUTION meter in order to engage the internal ring of bearing without
engaging the cage.
Use only new screws.

ASSEMBLY
FIGURE 36: Only if bearings are replaced, insert the thrust FIGURE 39: Position the differential unit in the central body
blocks of the bearings into the intermediate covers. with the help of a bar and fit the middle cover.
36 37 C
38
FIGURE 37: Thoroughly check the condition of the o-ring (36, FIGURE 40: Tighten the two safety screws “C” into the main
37). body (28) and install the intermediate cover (38).
Loctite 242 Loctite 242

35 140 N·m 140 N·m
33
FIGURE 38: Fit the intermediate cover (33) on opposite side FIGURE 41: Tighten screws to a torque of 140 N·m.
of ring gears: lock cover with screws (35) coated with Loctite
242.
Tighten screws to a torque of 140 N·m.

ASSEMBLY
1/4 turn
T1 2
FIGURE 42: Only if ring nuts have been removed, tighten the FIGURE 45: Introduce a gauge “A” with long tracer through
ring nut (2) on ring gear side until clearances between pinion the hole provided for the cap. Position the tracer on the side of
and ring gear are zeroed. Then, loosen by about 1/4 turn. a tooth of the ring gear, approximately 5 mm from the outer
rim; preload by about 1 mm and zero the gauge.
Gap = 0,25 - 0,33 mm
T1 26
FIGURE 43: Only if ring nuts have been removed, preload be-
arings with ring nut (26) on non-ring gear side in order to in-
crease the torque of the pinion. FIGURE 46: As you hold the pinion in position, move the ring
gear manually in both directions to check clearance between
pinion and ring gear. Standard clearance: 0,25 - 0,33 mm
CAUTION
In the case of used bearings, check thrust torque; in the
case of new bearings, check continuous torque.
2 26
1 27
TM
FIGURE 47: If torque and/or pinion-ring gear clearance is not

within tolerance values and the ring nuts have not been remo-
ved, mark the position of the ring nuts (2, 26) and remove the
FIGURE 44: Apply torque meter TM to pinion nut and check
safety plates (1, 27).
that torque will increase by 20 - 40 N·cm as a result of diffe-
rential bearing preload.
Example: pinion torque: 120 - 130 N·cm Pinion + differential
torque: 140 - 170 N·cm.

ASSEMBLY
T1
FIGURE 48: Adjusting clearance between pinion and ring gear. FIGURE 51: Install the complete arm.
To INCREASE: loosen the ring nut on ring gear side and tighten
the ring nut on non-ring gear side by the same measure.
To DECREASE: perform the same operations inversely. To ro- 283 - 312 N·m
tate ring nuts, use special wrench T1 (See drawing T1 p. 79).
Loctite 242
24 - 26 N·m
FIGURE 52: Torque wrench setting: 283 - 312 N·m.
NOTE:
Tighten using the criss-cross method.
FIGURE 49: Engage screw (27) in the slot next to the holes
provided for the check screws.
Coat screws (27) with Loctite 242 and tighten to a torque of
24 - 26 N·m.
FIGURE 50: Fit the top plug after applying repositionable

jointing compound for seals to the rims. Install the snap ring.

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2379
¯ 166
10 x15
¯ 40.5 ---- 0.1
0.2
0.8
¯ 15H7-n6
100
¯ 14
2 x15
8
0.8
24
17
20
238
0
R1 ¯ 25
¯ 10
¯ 35
123
125
33
36
¯ 37H7-n6
¯ 47
¯ 143 0.1
R 30
25

SPECIAL TOOLS

BEVEL PINION
EXPLODED VIEW
3 6
2
14
15
17
7
1
8
13
10 16
11
12

DISASSEMBLY
DISASSEMBLY
CAUTION
see OIL DRAINING MANDATORY PROCEDURE p. 12. T1
FIGURE 3: Position tool T1 (See drawing T1 p. 90), so as to

avoid pinion rotation.
Loosen and remove the nut (1) and o-ring (11).
2
FIGURE 1: Remove both axle arms.
1
80C°
10
11 10
1 10
FIGURE 2: If disassembly is difficult, heat the check nut (1) of

the flange (10) to 176 °F [80 °C].
NOTE:
Heat will loosen the setting of Loctite on the nut (1).
10
FIGURE 4: Remove the flange (10) complete with guard (2).

DISASSEMBLY
9
FIGURE 5: Remove the sealing ring (9). FIGURE 8: Using a puller and a press, remove the inner bea-
ring (5) from the pinion (6).
T2
FIGURE 6: Apply blocks T2 (See drawing T2 p. 91) and, with
the help of a puller, extract the pinion (5) complete with the in- FIGURE 9: Remove the thrust block of the external bearing
ternal bearing (6), the spacer (8), and calibrated spacer (4, 7). (3).
NOTE:
The thrust blocks of the bearings remain in the central
body (12).
17
7
FIGURE 10: Insert a drift in the appropriate holes.
FIGURE 7: Remove spacer (17) and calibrated spacer (7).

DISASSEMBLY
4
6
FIGURE 11: Remove the thrust block of the internal bearing
(6) as well as the shim washers (4).
15
FIGURE 12: Remove the snap ring (15).
14
FIGURE 13: Remove the cap (14).

ASSEMBLY
ASSEMBLY
I = 135
M5
- 0,1 = Y
42 mm
FIGURE 16: Check nominal dimension “I” as marked on the
pinion. Add up to or subtract from “I” the variation indicated
FIGURE 14: CALCULATING PINION CENTER stud as “Y” to obtain the actual center stud “I”.
Using a faceplate, reset a dial indicator “DG” on a calibrated EXAMPLE: I = 135 - 0.1 = 134.9
block (whose known thickness is 42 mm.).
Preload the gauge by about 3 mm. NOTE:
M5 = Match part number
D
9
FIGURE 15: Bring inner bearing (6), complete with thrust

block, under gauge “DG”. FIGURE 17: Calculate shims "S" for insertion under the thrust
EXAMPLE: 42 +0.5 = 42.5 = “D”. block of the inner bearing using the following formula:
S = 178 - (I+D)
where: 178 = fixed dimension;
CAUTION I = actual pinion center stud;
D= total bearing thickness;
Press the thrust block centrally and carry out several mea- EXAMPLE: S = 178 - (134.9 + 42.5) = 0.6 mm.
surements by rotating the thrust block.

ASSEMBLY
T3
A
DDG
A
6
4
T4 T4
3
FIGURE 18: Using special tool T3 (See drawing T3 p. 91) par- FIGURE 21: Introduce the tracer of a depth gauge “DDG” into
tially insert the thrust block of the bearings (3, 6) and shims (4). either side hole of tool T4 (See drawing T4 p. 92). Reset the
gauge with a preload of about 3 mm.
3
FIGURE 19: Connect the tension rod to the press and move
the thrust block of bearings (3, 6) into the seats. FIGURE 22: Remove the gauge and take out tool and bearing
Disconnect the press and remove the tension rod. kits from the main body.
Reinstall every part, also introducing a spacer between bea-
NOTE: rings (3) and (6). Tighten the entire pack by hand.
Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
T4
12
H = A - B = 1,8 mm
FIGURE 23: Introduce depth gauge “DDG” in tool T4 (See
3 T4 drawing T4 p. 92) and measure deviation “H” from the pre-
vious reset.
FIGURE 20: CALCULATING PINION BEARINGS ROLLING
EXAMPLE: H = A - B = 1,8 mm.
TORQUE
Introduce tool T4 (See drawing T4 p. 92) complete with bea-
rings (3) and (6) into the main body (12); tighten by hand until
a rolling torque is definitely obtained.

ASSEMBLY
17
7
S1 7
FIGURE 24: Deviation “H” must be added to a set value of FIGURE 27: Refer and keep to the positions marked during
0.12--0.13 mm (X) to obtain calibrated spacer “S1” (7) for in- disassembly.
sertion between inner bearing (6) and spacer (8).
Dimension “S1” must be rounded off to the higher 5/100.
EXAMPLE: S1 = H + X = 1,8 + (0.12 - 0.13) = 1,92 - 1,93 mm.
5 5
100°
FIGURE 28: Fit the pinion (5), calibrated spacer “S1” (7) and
6 spacer (8) in the main body (12).
FIGURE 25: Heat the inner bearing (6) to about 212 °F [100
°C] and fit it onto the pinion (5).
NOTE:
Once the bearing has cooled down, lightly lubricate bea- 5
ring (6) with SAE85W90 oil.
FIGURE 29: Heat the external bearing (3) to a temperature of

about 212 °F [100 °C] and fit it on to the pinion (5) to complete
6 the pack as shown in the figure above.
NOTE:
Lightly lubricate bearing (3) with SAE85W90 oil.
FIGURE 26: Make sure that the bearing (6) is well set.

ASSEMBLY
120 - 180 N·cm
10
FIGURE 30: Install the flange (10) onto the pinion (5) without FIGURE 32: Apply onto the pinion (5) the bar-hold and with
the sealing ring. the help of a torque meter, check the torque of the pinion (5).
Torque: 120 - 180 N·cm
Loctite 242
800 - 1000 N·m CAUTION
If torque exceeds the maximum value, then the size of cali-
brated spacer “S1” (7) between the bearing (6) and the spa-
cer (8) needs to be increased. If torque does not reach the
set value, increase the torque setting of the ring nut (1) in dif-
ferent stages to obtain a maximum value of 800 - 1000 N·m.
If torque does not reach the minimum value, then the size of
calibrated spacer “S1” (7) needs to be reduced.
When calculating the increase or decrease in size of calibra-
T1 terd spacer “S1”, bear in mind that a variation of calibrated
spacer (4) of 0.01 mm corresponds to a variation of 60 N·cm
FIGURE 31: Apply wrench to the ring nut (1) and bar-hold T1 in the torque of the pinion (5).
(See drawing T1 p. 90) to the pinion (5). Lock the wrench T1
(See drawing T1 p. 90) and rotate the pinion using a torque
wrench, up to a minimum required torque setting of 800 - 10
1000 N·m.
FIGURE 33: Make positional marks across nut (1) and pinion
(5) tang; then remove nut and flange (10)

ASSEMBLY
12
9 T5 T1
FIGURE 34: Apply Arexons rubber cement to the outer surfa- FIGURE 37: Tighten the nut until the match marks line up.
ce of the new seal ring (9) and fit ring in the main body (12)
using driver T5 (See drawing T5 p. 93).
FIGURE 35: Fit the safety flange (2).
Loctite 242
10 11
FIGURE 36: Oil seal ring lips and install flange (10).
Mount o-ring (11) and apply Loctite 242 to pinion tang; tighten
nut (1).

SPECIAL TOOLS
SPECIAL TOOLS
T1
P/N: 2308
¯ 185 0.2
0.2
120
80
¯ 105
25 ¯ 105 0.2
125
10
15
25
125
¯ 34.5 --+ 00.2

¯ 50
135 0.5
97
73
61.5
61.5
85
126 12
¯ 32 150
10
15
100
¯ 45

SPECIAL TOOLS
T2
P/N: 2381
90
¯17
25
131
20
T3
P/N: 2377
38
122
8
R 10 5
0.8
R2
25
0 .8
21.5 19.5
0 .8
¯ 104
¯ 109
¯ 55
¯ 69
¯ 85
¯ 89
¯ 35
¯ 70
¯ 80
R3
0.8
¯ 19.5
M18 x 1.5
R2
0.8
27 25
28
10 85
30 3 x 15
0.8
¯ 35
0.8
450 80 ¯ 25
¯ 19.5
M18 x 1.5
550
Cylinder
Thrust block
Thrust block
Differential box

SPECIAL TOOLS
T4
P/N: 2374
¯ 60
30
¯ 6
1/4"
0.8
12
70
0.8
128
3 x 15
38
0.8
M16 x 1.5
20
¯ 20
-0.2
¯ 50 -0.4
-0.2
¯ 40 -0.4
0.8
¯ 20
3 x 15
M16 x 1.5
0.8
40
65
67
119
¯ 5
163
3 x 15
0.8
-0.02
¯ 50 -0.04
37
0.8
10
44
0.8
A-A
10
¯ 70

SPECIAL TOOLS
T5
P/N: 2375
¯ 50
30
3x45
110
158
195
125
1 x 45
R5
28.5
R3
6
16.5 +-- 0.0 2
3 x 15
12
0.8
¯ 39.5
0.8
¯ 61.5 + 00.1
¯ 85
¯ 98
¯ 125

SPECIAL TOOLS

LIMITED SLIP DIFFERENTIAL UNIT
EXPLODED VIEW
14
13
14 12
13
11
12 9
12
11
8
13
10 14
12
7
15
13
5 14
4
3
7

DISASSEMBLY
DISASSEMBLY
4
CAUTION
see OIL DRAINING MANDATORY PROCEDURE p. 12. 2
FIGURE 3: Make positional match marks on the half boxes of

the differential gear (2); loosen and pull out joining screws (4).
FIGURE 1: Remove the whole differential unit (2) from the

main body (1). 7
(For details, see DIFFERENTIAL UNIT p. 69).
5
CAUTION
The following section includes clutch replacement procedu-
res only; for gear ring replacement, see DIFFERENTIAL
UNIT p. 69. FIGURE 4: Remove the upper half box (5) and clutch pack (7).
CAUTION
Check and write down the amount of differential discs.
In function of this quantity deduce the type of material:
3 8 discs - friction material "PAPER"
10 discs - friction material "MOLY"
CAUTION
If the clutch pack does not need replacing, avoid swapping
discs position.
FIGURE 2: Using a puller, remove bearing (3).

DISASSEMBLY
CAUTION
8
If the clutch pack does not need replacing, avoid swapping
discs position.
9
FIGURE 5: Remove the crown wheel (8) and planetary gears

set (9).
10
FIGURE 6: Remove the 2nd planetary gear (10).
11
FIGURE 7: Remove the 2nd clutch pack (11) .
CAUTION
Check and write down the amount of differential discs.
In function of this quantity deduce the type of material:
8 discs - friction material "PAPER"
10 discs - friction material "MOLY"

ASSEMBLY
ASSEMBLY
“MOLY” FRICTION DISCS “PAPER” FRICTION DISCS
V V
14 12 14 12
8 10 8 10
13 13
FIGURE 8: Check the disc pack thickness “V” applying 3000 FIGURE 9: Check the disc pack thickness “V” applying 3000
N ± 5%. N ± 5%.
“V” measurement must be 17,4 ± 0,08 mm. “V” measurement must be 17,35 - 17,50 mm.
CAUTION CAUTION
Dip the complete disc pack in oil (with LS additive) at least Dip the complete disc pack in oil (with LS additive) at least
one hour before to assembly, for details about oil see OIL 24 hours before to assembly, for details about oil see OIL
DRAINING MANDATORY PROCEDURE p. 12. DRAINING MANDATORY PROCEDURE p. 12.
NOTE: NOTE:
Check the total dimension of the disc pack before instal- Check the total dimension of the disc pack before instal-
ling, if this measurement does not respect the predifined ling, if this measurement does not respect the predifined
value install a new disc pack. value install a new disc pack.
New disc pack doesn’t need measurement, because, New disc pack doesn’t need measurement, because,
supplied as subassembly, they already respect the predi- supplied as subassembly, they already respect the predi-
fined value. fined value.
It is mandatory to install discs of the same material of the It is mandatory to install discs of the same material of the
original installation. original installation.
11
FIGURE 10: Fit the clutch pack (11) in the half-box.
CAUTION
When installing the increased shim, place shim so that it le-
ans against the crown wheel (8, 10).

ASSEMBLY
10
FIGURE 11: Install planetary gear (10).
FIGURE 12: Fit the planetary gear set (9).

Mount second planetary gear (8).
NOTE:
Make sure that spherical thrust washers (15) are present.
7
5
FIGURE 13: Fit increased shim (12), clutch pack (7) onto the
crown wheel (8).
Fit the upper half box (5) and make sure that the match marks
line up.
Complete the assembling operation and install the differential
unit following the procedures described in the first part of the
manual under section DIFFERENTIAL UNIT p. 69.

ASSEMBLY

SWINGING SUPPORT
EXPLODED VIEW
Bushing cut position

DISASSEMBLY
DISASSEMBLY
4 Bushing cut position

FIGURE 1: Remove the swinging support (4).
44
FIGURE 2: Remove the swinging support (4) on the side op-
posite the drive.
FIGURE 3: Position the swinging support (4) under a press

and remove the complete bushing (3).

ASSEMBLY
ASSEMBLY
A 33
4
4
FIGURE 6: Install the swinging support (4).

reference direction A
FIGURE 4: If the bushing (3) is worn and needs replacing, wri- NOTE:
te down the assembly side of the connection notch “A“. Check that it is properly oriented.
Bushing cut position
reference direction A
4
4
FIGURE 7: Install the swinging support (4) on the side oppo-

site the drive.
4
4
FIGURE 5: Position the swinging support (4) under a press

and insert the complete bushing (3).

ASSEMBLY

SERVICE BRAKE
EXPLODED VIEW
7
8
5
6
9
10
11
12
13
14

DISASSEMBLY
DISASSEMBLY
DANGER
Before maintaining brakes, when the axle is installed on the
vehicle, follow all safety instructions in the Original Equip-
ment Manufacturer (OEM) manual that came with the vehi-
cle.
CAUTION
see OIL DRAINING MANDATORY PROCEDURE p. 12. Down Side
FIGURE 3: Write down the counterwasher (1) position.
Differential side Arm side

hoist. Loosen and remove screws.
FIGURE 4: Write down the flange (4) position.
1
3
FIGURE 2: Write down the order of assembly and remove the

counterwasher (1). FIGURE 5: Remove braking discs (2, 3), noting down direc-
tion of assembly.
NOTE:
If disks are not to be replaced, avoid changing their posi-
tion.

DISASSEMBLY
reversal springs
FIGURE 6: Remove the flange (4) complete with the discs.
5
FIGURE 9: Remove the adjusting screws (5)
FIGURE 7: Remove braking discs (2, 3), noting down direc-

tion of assembly.
NOTE:
If disks are not being replaced, avoid changing their posi-
tion.
7
adjusting screws
FIGURE 8: Remove the reversal springs (7)

DISASSEMBLY
9
CAUTION
damaged.

ASSEMBLY
ASSEMBLY
Drilock
10 - 15 N·m
FIGURE 14: Fit the reversal springs screws (7) on the piston
(9). Tighten with torque wrench setting of 10 - 15 N·m
FIGURE 11: Insert the stroke automatic regulation springs (6);
place them in line with the piston (9).
CAUTION
sive. Threads must be cleaned from oil.
12 Degrease only non pre-treated threads.
10
Drilock
5 - 7 N·m
13
FIGURE 12: Fit o-ring (11, 12) and back-up ring (10, 13) onto
the piston (11).
Lubricate the piston and the o-rings and install the unit into
the arm (14).
FIGURE 15: Fit the adjusting screws (5).

Torque wrench setting: 5 - 7 N·m.
CAUTION
sive. Threads must be cleaned from oil.
Degrease only non pre-treated threads.
14
FIGURE 13: Using a plastic hammer, install the piston (9) into
the arm (14).
reversal springs
NOTE:
quence.
adjusting screws
ASSEMBLY
first disc
1
FIGURE 16: Insert the brake discs in the correct sequence. FIGURE 19: Insert the intermediate disk (1).
NOTE:
The first brake disc (2) to be inserted must be of metal
material.
second disc
FIGURE 20: Check condition and position of the cylinder's o-

ring.
FIGURE 17: The second brake disc (3) to be inserted must be

of friction material.
NOTE:
The last brake disc to be inserted must be of friction ma-
terial.
Up side
Loctite 242
200 - 221 N·m
FIGURE 21: Cross tighten the nuts in two stages.
Torque wrench setting: 200 - 221 N·m
FIGURE 18: Install the flange (4) on the arm.

ASSEMBLY

Copyright 2015 Dana Holding Corporation For product inquiries or support,
All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445
be reproduced in whole or in part by any means, For other service publications,
electronic or otherwise, without prior written approval. visit www.SpicerParts.com/literature.asp
THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
RESALE, AND THIS NOTICE MUST REMAIN ON ALL visit www.SpicerParts.com/order.asp
COPIES.

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Service Manual

ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 3

4 Dana Holding Corporation ASM-0029E - 223 Axle Service Manual

ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 5

1 - Type and model unit - modification index

ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 7

Atm Bar MPa Pa PSI

Atm 1 1 0,1 105 14,4

Bar 1 1 0,1 105 14,4

MPa 10 10 1 106 144

Pa 0,00001 0,00001 10-6 1 -

1N 1 0,1 0,001 0,102 0,225

1daN 10 1 0,01 1,02 2,25

1kN 1000 100 1 102 225

1kg 9,81 0,981 0,00981 1 2,205

N·m daN·m kN·m kg·m lb·in

1N·m 1 0,1 0,001 0,102 8,854

1daN·m 10 1 0,01 1,02 88,54

1kN·m 1000 100 1 102 8854

1kg·m 9,81 0,981 0,00981 1 86,8

1 lb·in 0,1129 0,01129 0,0001129 0,01152 1

8 Dana Holding Corporation ASM-0029E - 223 Axle Service Manual

SIZE OF BOLT TYPE OF BOLT

M10 x 1,5 mm 48 – 53 N·m 52 – 58 N·m 68 – 75 N·m 73 – 81 N·m 80 – 88 N·m 88 – 97 N·m

SIZE OF BOLT TYPE OF BOLT

ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 9

WHEEL NUT TIGHTENING TORQUES

WHEEL NUT TIGHTENING TORQUES

RECOMMENDED WHEEL NUTS TORQUE

CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY

WHEEL NUTS WITH M18 x 1,5 mm 330 N·m 460 N·m

FLAT COLLAR WHEEL M18 x 1,5 mm 270 N·m 360 N·m

**RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS. IT IS THE OPTIMUM MA-

DANA OFFICIAL TIGHTENING TORQUE TABLE

M18 x 1,5 mm M18 x 1,5 N·m 442 ÷ 489 N·m

M20 x 1,5 mm M20 x 1,5 N·m 613 ÷ 677 N·m

M22 x 1,5 mm M22 x 1,5 N·m 822 ÷ 908 N·m

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ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 11

OIL DRAINING MANDATORY PROCEDURE

PLANETARY GEAR REDUCTION

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ASM-0029E - 223 Axle Service Manual

or GL5) Clean carefully oil plug magnet.

Negative brake (SAHR) For hydraulic actuations Not applicable

In case of severe duty, half oil change intervals must be applied.

Dana Holding Corporation

LUBRICANT & SEALANT SPECIFICATIONS

14 Dana Holding Corporation ASM-0029E - 223 Axle Service Manual

Indicates an imminently hazardous situation

Indicates information which may make product

ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 15

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ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 17

3 FIGURE 5: Remove safety flange (6).

FIGURE 2: Alternately insert a lever in the slots provided and

FIGURE 6: Remove the complete ring gear flange (5) by using

FIGURE 3: Remove the complete planetary cover (2).

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ASM-0029E - 223 Axle Service Manual Dana Holding Corporation 19