Service Manual
Contents
1. 8 Check the rotation of the pinion a Verify the pinion rotation torque is 4 9 Ibs in 0 45 1 06 Nem b If the pinion does not turn within specification FIGURE 77 adjust the shim pack G Add shims if rotation 4 Install the pinion with bearing B amp C spacer F and torque is too high remove shims if rotation shim G torque is too low NOTE Number on pinion and ring gear indicate matched set Make sure numbers on ring and pinion gears match before assem bling FIGURE 78 5 Install the bearing cone 1 using the Pinion Bearing Driver Tool page 35 ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 22 Center Section Assembly amp Installation A Differential Case B Bearing C Shim D Ring Gear E Bolts FIGURE 81 FIGURE 82 9 Install the ring gear D to the differential A tightening the ring gear bolts E 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 83 10 Drop axle shaft in the long housing Place the differ ential assembly with bearings in the long trumpet housing on axle shaft 23 Dana Holding Corporation FIGURE 84 11 Place original shims C on the differential bearing B and install the short housing FIGURE 85 12 Install 4 bolts torqued to 50 55 Ibs ft 68 75 Nem FIGURE 86 13 Set backlas2. lt pana gt SPICER Off Highway Products service Manual Axle S20BZ128 1 ASM 0168 March 2014 CONTENTS MAINTENANCE 8 LUBRICATION 2 1 Dala Plate isses 1 Definition Of VIEWPOINTS esse RR EE EER RR EE RR RR RE 1 Maintenance Points oononnnnnnnnnnnnn KERE EER R KEER ERK EE 2 Maintenance Intervals oooronnnnnnnnnnnnnn RE ERK RR Ee 2 SAFETY PRECAUTIONS iis a i ee Dress 3 DISASSEMBLY 8 REASSEMBLY dates 4 Exploded RTE 4 Driveshaft amp Hydraulic Line Removal 5 Axle Removal nase 5 Steering Cylinder Removal seke EE 5 Tie Rod Removal ha 6 Drain Plug Removal unnnnennnnannunnnnnnnennnnnnnnnnnnnnnnnn 6 Final Drive Cover Disassembly sesse EER REKE 6 Final Drive Cover Installation sesse see eek RR EER ee 8 Drop Shaft amp Knuckle Disassembly 9 Drop Shaft amp Knuckle Assembly ooononnnnnnnmmu 11 Shoulder Disassembly ooouunnnnnnnn nn nn 13 Shoulder Assembly ia an 15 Face Seal Installation ia 17 Center Section Removal amp Disassembly 18 Center Section Assembly amp Installation 21 Drain Plug Installation esse ee EER RR EER RR EE RR RR RE 25 Tie Rod Installati n EERS EN DE 26 Steering Cylinder Installation essens RR RR RE ER 26 Axle Trunnion Installation sesse kke ER RR EE RR EE 27 Axle Installation amp Toe in Adjustment 28 Driveshaft amp Hydraulic Line Installation 28 SPEBIAFTOOES AA 29 Fa
3. Every 200 hours verify Thrust bolt torque 10 11 Ibs ft 13 15 Nem Jam nut 22 26 lbs ft 30 35 Nem Initially after 10 working hours Every 200 hours DanaHolding Corporation Oil Check Levels Every 50 hours check level on dipstick J20C 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 working 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
4. Steering Cylinder 34 Tie Rod 33 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Pinion Seal Tool Pinion Seal Tool p60 CA Oos KNURLING D50 Material 20MnCr5 Harden 55 60 HRc ASM 0168 S20BZ128 1 Axle Service Manual DanaHoldingCorporation 34 Pinion Bearing Driver Tool Pinion Bearing Driver Tool 100 KNURLING Material 20MnCr5 Harden 55 60 HRc 35 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Welch Plug Driver Tools Welch Plug Driver Tools Center Housing lt r 49444 P A AR EIE AS db s 7 7 7 002 Z Z YA 011 Z 7 e Z Z Es Z Fa we V Ga 7 WEL 7 AAR AA CMA ppt Vida L YA Z Z a 46 7 CE 7 7 4111 ZD 47 SLZY lfp 44 47 47 J 2 Ur 7 IPA F 7 f f v IPA v P Z Z 4 2 7 s v J Z Z 7 4 J 7 Z Z 7 7 IE EL v Z 46 7 Z Za 6 Magnet 6mm Diameter Shoulder Knuckle 86 EE ee z T g sif 9L Be OR 84 sie LEB ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 36 Knuckle to Trumpet Assembly Tool Knuckle to Trumpet Assembly Tool 3 2000 UU 16 00 u 100 00 2 16 00 100 0
5. 006 0 010 in 0 15 0 25 mm 15 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Shoulder Assembly FIGURE 53 5 Install the top welch plug A using the Welch Plug Driver Tools page 36 The welch plug should always be replaced Do not reuse FIGURE 54 6 Install welch plug and snap ring J from shoulder ASM 0168 S20BZ128 1 Axle Service Manual k gt P A FIGURE 55 7 Install shoulder face seal cup K using the Face Seal Cup Driver page 31 The face seal cup C should always be replaced Do not reuse 8 Install face seal C using the Face Seal Tool page 29 See Face Seal Installation on page 17 FIGURE 56 9 Install spacer L on housing 10 Install drop shaft and knuckle assembly See Drop Shaft amp Knuckle Assembly on page 11 11 Install final drive cover See Final Drive Cover Instal lation on page 8 Dana Holding Corporation 16 Face Seal Installation Face Seal Installation The face seal cup should always be replaced Do not reuse Replace damaged seals If metal face seals are dam aged the face seal o rings should also be replaced Clean metal face seal rings with a non petroleum based solvent 1 Housing components that contact the rubber seal must be free from foreign material oil grease dirt metal chips dust or lint particles etc before install ing the seal This should be done us
6. G using the Face Seal Cup Driver page 31 on the final drive cover E See Face Seal Installation on page 17 for clean ing of face seal The face seal cup G should always be replaced Do not reuse FIGURE 17 3 Using the Face Seal Tool page 29 install the face seal H half on the output shaft I and half on the final drive cover E FIGURE 18 4 Press the final drive cover E to the output shaft I ASM 0168 S20BZ128 1 Axle Service Manual FIGURE 19 5 Press bearing D to the bevel gear C Press the bevel gear C to the final drive cover and output shaft assembly E amp l FIGURE 20 6 Select shims B such that the maximum gap between shim and snap ring is 0 1 mm check gap with feeler gauge Dana Holding Corporation 8 Drop Shaft amp Knuckle Disassembly Drop Shaft amp Knuckle Disassembly Saar a x D 2 in AT ag attr AF M m i ry m ka alt 4 3 A Va F Pi a 1 k Ba Va bi gt A a ff ef Ze Ser AA gt K 1 D lege ei 27 T FIGURE 22 i 8 Remove final drive cover assembly See Final Drive FIGURE 21 Cover Disassembly on page 6 7 Install final drive cover to knuckle housing tightening capscrews to 24 28 lbs ft 32 38 Nem FIGURE 23 9 Carefully remove welch plug from knuckle housing FIGURE 24 10 Remove snap ring from knuc
7. 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 ward After repair work has been completed accurately touch up any coated part that may have been damaged Follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Indicates an imminently hazardous situation which if not 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 0168 S20BZ128 1 Axle Service Manual DISASSEMBLY amp REASSEMBLY Exploded View ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 4 Driveshaft a Hydraulic Line Removal Driveshaft amp Hydraulic Line Removal Disconnect the
8. 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 d 2 Bushings FIGURE 2 2 Remove front and rear trunnions Inspect axle pin bushings and replace if reguired NOTE When removing the rear trunnions also remove the thrust washer and both v rings mounted on the housing When removing the front trunnion also remove the v ring and thrust washer o Dana Holding Corporation Steering Cylinder Removal FIGURE 3 1 Remove cotter pins castle nuts and washers FIGURE 4 2 Remove steer cylinder NOTE Cylinder 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 0168 S20BZ128 1 Axle Service Manual Tie Rod Removal Tie Rod Removal FIGURE 5 1 Remove the cotter pin and the castle nut from tie rods FIGURE 6 2 Using a tie rod end removal tool remove tie 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 reus
9. 0 o 150 thread length 37 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual
10. 15 130 Nem ASM 0168 S20BZ128 1 Axle Service Manual Steering Cylinder Installation Steering Cylinder Boots FIGURE 101 1 Inspect steering cylinder boots replacing as needed FIGURE 102 2 Install cylinder with castle nuts tightened to 74 85 lbs ft 100 115 Nem Install cotter pins If slots in castle nut do not line up with cotter pin holes con tinue tightening nut until next slot aligns 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 103 2 Insert the rear bushing E on the rear trunnion F Ensure the hole in the bushing is oriented in the 12 o clock position 3 Install v ring and v ring seal B on center section pin A 4 Install the thrust washer C on the rear trunnion F bore It might be necessary to apply grease to the thrust washer to hold it in place 5 Install v ring and v ring seal D in the rear trunnion F 6 Slide rear trunnion F on center section A pin Grease Zerk FIGURE 104 7 Grease the rear trunnion after installation using the grease zerk G until grease purges out from the v ring Assemble Front Trunnion 12 o clock position FIGURE 105 1 Install bushing B in front trunnion A 2 Install the thrust plate C on the front trunnion A It might be necessary to apply grease to th
11. ation 1 Position driveshaft onto machine While supporting drive shaft slide splined connector toward machine 2 Install spring pin to drive shaft splined connector 3 Connect steering cylinder hydraulic lines ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 28 SPECIAL TOOLS Face Seal Tool Left Hand Side R05 TYP BOTH GROOVE 855 0 2X45 TYP BOTH GROOVE a Material 20MnCr5 Harden 55 60 HRc 29 Dana Holding Corporation 9 4 13 i d i 127 LL UNE ASM 0168 S20BZ128 1 Axle Service Manual Face Seal Tool Right Hand Side SUITABLE TO PIN R0 5 TYP BOTH GROOVE geg 735 980 5 0 2X457 CHMF TYP BOTH GROOVE Material 20MnCr5 Harden 55 60 HRc ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 30 Face Seal Cup Driver Face Seal Cup Driver Shoulder i 17 E ZI 1 e d i Knuckle J VI 80 15 121 85 Final Drive Cover i a i i i NA O CO ol Dm T gy SO RS M gt 1 1 1 10715 30 31 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual 8 Ben gt Be O Ben o mM xX O C Z SY 7 N Las WAA I LSS ng Driver Knuckle Beari Steering Cylinder amp Tie Rod Removal Tool Steering Cylinder amp Tie Rod Removal Tool
12. ce Seal Kee WE 29 Face Seal Cup Driver iii 31 Knuckle Bearing Driver Tool erens RR RE EER RR EE 32 Steering Cylinder amp Tie Rod Removal Tool 33 Pinion Seal 100 sans 34 Pinion Bearing Driver TOO essens eek Rea ERK RR Ra 35 Welch Plug Driver ToolS sssssscsecssssseseserseeeneenss 36 Knuckle to Trumpet Assembly Tool 37 ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation MAINTENANCE 8 LUBRICATION Data Plate Model Number 1 Build Date DDMMYY T Serial Number Definition of Viewpoints LEFT SIDE IS RIGHT SIDE lt gt DIRECTION 1 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Maintenance Points 1 Oil fill plug 2 Oil drain plug 3 Check level plug 4 Grease zerk 5 Front trunnion thrust bolt Maintenance Intervals m Greasing Front 8 Rear Trunnion Front Trunnion Bolt Wheel Nuts ASM 0168 S20BZ128 1 Axle Service Manual Tightening Maintenance Points Front Trunnion Rear Trunnion Freauenc Initially after 100 working hours Every 600 hours Drain plug torque 16 20 Nem Dry land applications Weekly or every 50 hours whichever is earlier Wet land applications Daily
13. e Manual Drop Shaft amp Knuckle Assembly FIGURE 35 6 Assemble shim F and snap ring G on the trumpet spindle ensuring a maximum end play of 0 004 in 0 1mm check gap with feeler gauge FIGURE 36 7 Install final drive cover assembly to knuckle housing See Final Drive Cover Installation on page 8 FIGURE 37 8 Install bevel gear and bearing assembly I amp J any shim s K and snap ring L on drop shaft 9 To set lower final drive backlash shim G the bevel gear end play to 0 028 0 038 in 0 71 0 96 mm ASM 0168 S20BZ128 1 Axle Service Manual FIGURE 38 10 The end play sets backlash to 0 006 0 008 in 0 15 0 20 mm fa FIGURE 39 11 Remove bevel gear and bearing assembly and install drop shaft H 2 4 x FIGURE 40 12 Reassemble bevel gear and bearing assembly I amp J shim K and snap ring L Dana Holding Corporation 12 Shoulder Disassembly Shoulder Disassembly 1 Remove final drive cover assembly See Final Drive Cover Disassembly on page 6 2 Remove drop shaft and knuckle assembly See Drop Shaft amp Knuckle Disassembly on page 9 FIGURE 41 13 Apply Loctite 380 480 to a new welch plug M and install to Knuckle housing using the Welch Plug Driver Tools page 36 FIGURE 42 The welch plug should always be replaced Do not reuse 3 Remove the top welch plug FIGURE 43 4 Remove
14. ed 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 0168 S20BZ128 1 Axle Service Manual Final Drive Cover my FIGURE 8 1 Remove capscrews from final drive cover EE e LA geg Fat a hi DCH kt Sai LA A gt ag e FIGURE 9 2 Separate final drive cover and output shaft from final drive housing NOTE It may be necessary to pry the cover from the housing using the two pry bars on each side of the cover FIGURE 10 3 Remove the snap ring and shim Dana Holding Corporation 6 Final Drive Cover Disassembly FIGURE 11 4 Remove bevel gear from output cover FIGURE 14 7 Remove face seal from the output shaft Bearings FIGURE 15 8 If necessary press bearings off of bevel gear and output cover FIGURE 12 5 Remove the output cover FIGURE 13 6 Remove face seal from the output cover FIGURE 16 9 Clean and inspect all parts replacing any damaged components 7 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Final Drive Cover Installation Final Drive Cover Installation A Snap Ring B Shim C Bevel Gear D Bearing E Final Drive Cover F Bearing G Face Seal Cup H Face Seal Output Shaft Press bearing F to the final drive cover E 2 Install the face seal cup
15. h to 0 004 0 006 in 0 1 0 15 mm using a dial indicator through the window provided in the long housing If backlash is not to spec adjust the shim to set the correct backlash elncrease shims to reduce backlash Decrease shims to increase backlash ASM 0168 S20BZ128 1 Axle Service Manual Center Section Assembly amp Installation 1 FIGURE 87 14 Once backlash is set remove the four 4 bolts used for the temporary assembly and remove the short housing FIGURE 88 15 Install the right hand axle shaft FIGURE 89 16 Apply Loctite 515 evenly to the surface of the trum pet housing ASM 0168 S20BZ128 1 Axle Service Manual FIGURE 90 17 Install the short housing to the long housing by applying Loctite 262 to all capscrews and torguing to 50 55 Ibs ft 68 75 Nem FIGURE 91 18 Remove spacer K slinger M spacer N and old pinion nut O FIGURE 92 19 Install new o ring J The o ring J should always be replaced Do not reuse Dana Holding Corporation 24 Drain Plug Installation Drain Plug Installation e th FIGURE 96 1 Apply Loctite 565 to center housing drain plug threads left photo above and tighten to 12 15 Ibs ft FIGURE 93 u 16 20 Nem 20 Install anew oil seal K using the Pinion Seal Tool Apply Loctite 565 to wheel end drain plug threads page 34 to sure ensure the seal seats correctly right photo above and
16. ing a lint free wipe and a non petroleum based solvent Dry with a clean wipe 2 Clean face seal o ring with isopropyl alcohol spray prior to installation to remove 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 FIGURE 57 FIGURE 58 4 Place the seal in the Face Seal Tool page 29 and locate this assembly squarely against the top of the conical seal 5 Spray the o ring and seat with isopropyl alcohol to act as a lubricant to the o ring 17 Dana Holding Corporation FIGURE 59 6 Use sudden and even pressure to push in the seal and ensure the retaining lip is not twisted or pinched 7 The sealing ring face should be parallel to the conical seal face within 0 50 mm see Figure 57 8 After installing the seal halves wipe both metal seal ing faces clean with a lint free cloth NOTE Metal face seals should be replaced when the distance between the seal inner diameter and seal contact band is less than 50 of the distance between the seal inner diam eter and the outer diameter 9 Then apply a coat of clean MS8 oil to the metal seal faces with a lint free applicator The oil must not wet surfaces other than the sealing faces 10 Clean the metal surfaces with
17. ing cone pinion bearing spacer m 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 wear or damage both must be replaced Remove the pinion nut spacer and slinger DO NOT discard nut at this time FIGURE 67 0 11 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 FIGURE 70 Always use a torque wrench to tighten correctly 14 Remove oil seal and bearing cone FIGURE 68 12 Remove spacer and o ring FIGURE 71 15 Remove both bearing cups being careful not to dam age housing surface 19 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Center Section Removal 8 Disassembly FIGURE 72 16 Remove shim with inner bearing cup P a FIGURE 73 17 Clean and inspect all parts replacing any damaged components ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 20 Center Section Assembly 8 Installation Center Section Assembly 8 Installation Pinion Assembly 1 Assemble bearing cone C to pinion B 73 FIGURE 74 2 Place inner shim s E under bearing cup D to set pinion height a If the original pinion and bearing are being used use the original shims or install new shims the same thickness as original shims 21 Dana Holding Corp
18. kle 9 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Drop Shaft amp Knuckle Disassembly FIGURE 25 11 Remove shim s from knuckle Save all shim s between the snap ring and bearing FIGURE 26 12 Remove bevel gear and bearing assembly along with drop shaft FIGURE 27 13 Remove snap ring and shim from knuckle housing ASM 0168 S20BZ128 1 Axle Service Manual FIGURE 28 14 Remove the knuckle housing from the trumpet arm FIGURE 29 15 Inspect all Knuckle and drop shaft parts replacing any unserviceable components Dana Holding Corporation 10 Drop Shaft amp Knuckle Assembly Drop Shaft amp Knuckle Assembly FIGURE 32 3 Install face seal A using the Face Seal Tool page 29 See Face Seal Installation on page 17 FIGURE 30 1 If removed press bearings C amp E into knuckle hous ing D using the Knuckle Bearing Driver Tool on page 32 FIGURE 33 4 Lubricate face seal A Gy FIGURE 31 2 Install the face seal cup B using the Face Seal Cup Driver page 31 on the knuckle housing D See Face Seal Installation page 17 for cleaning of face seal FIGURE 34 5 Install Knuckle on shoulder housing with spacer Assemble using the Knuckle to Trumpet Assembly The face seal cup B should always be replaced gt Do not reuse Tool on page 37 11 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Servic
19. lint free cloth 1 M568 oil is mineral based oil ranging from 10W to 90W ASM 0168 S20BZ128 1 Axle Service Manual Center Section Removal 8 Disassembly Center Section Removal 8 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 Ben ka d O FIGURE 63 5 Remove the differential assembly from left hand trumpet arm 6 Remove left hand axle shaft FIGURE 60 2 Properly support both halves of the azle Loosen the capscrews and remove the short housing FIGURE 64 7 Press off both bearings if necessary Then remove ring gear capscrews and ring gear from differential case FIGURE 61 3 Remove right hand axle shaft FIGURE 65 V 8 Remove top welch plug and inspect inside of case a 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 FIGURE 62 l 9 Clean and inspect all parts replacing any damaged 4 Remove the shim s from the right hand trumpet arm components ASM 0168 S20BZ128 1 Axle Service Manual Dana Holding Corporation 18 Center Section Removal amp Disassembly Pinion Disassembly FIGURE 66 10 Loosen pinion nut FIGURE 69 S 13 Remove pinion bear
20. oration 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 I Bearing Cone J O ring K Spacer L Oil Seal M Slinger N Spacer O Pinion Nut P Welch Plug Number A re gt 493 an AAN FIGURE 75 b If ring and pinion or bearing are being replaced notice the or number on the end of pinion or on pinion stem B This indicates the best running position of each particular gear set in thousandths of an inch If the number on the new set is not the same as the number on the one being replaced adjust the height by adding or removing inner shim s E from original shim pack according to dimension etched on the end of pinion or on pinion stem Example 1 If the old pinion reads 4 and the new pinion is marked 0 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 ASM 0168 S20BZ128 1 Axle Service Manual Center Section Assembly amp Installation FIGURE 79 6 Install the spacer K slinger M spacer N 8 OLD pinion nut O Spacer bore chamfer should be FIGURE 76 towards o ring 3 Using a Pinion Bearing Driver Tool page 35 assem ble bearing cups D amp H and shims E in the housing A FIGURE 80 7 Tighten the old pinion nut to 75 90 Ibs ft 102 122 Nem
21. rust plate to hold it in place 3 Install v ring and v ring seal D on center section E pin 4 Slide front trunnion A on center section E pin Grease Zerk e FIGURE 106 5 Grease the front trunnion using the grease zerk F until grease purges out from the v ring ASM 0168 S20BZ128 1 Axle Service Manual 27 Dana Holding Corporation Axle Installation amp Toe in Adjustment Axle Installation amp Toe in Adjustment FIGURE 107 6 Supporting the axle with a hoist and install axle into vehicle Install front wheels NOTE The toe in adjustment must be performed on the vehicle 7 Jack up front axle so tires are off floor 8 Rotate tire by hand and scribe a line near the center of each of the front tires NOTE One of the tie rod ends and jam nut has left hand threads FORWARD TOE IN SETTING DIFFERENCE IN LENGTHS B A TO BE 3 Omm 0 Omm FIGURE 108 9 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 10 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 11 Apply Loctite 262 and tighten the jam nuts to 85 96 lbs ft 115 130 Nem Driveshaft amp Hydraulic Line Install
22. snap ring shims and 14T bevel gear and bearing assembly from shoulder housing FIGURE 44 5 Remove 11T bevel gear and bearing assembly 13 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Shoulder Disassembly FIGURE 45 6 Remove the knuckle bearing spacer and face seal FIGURE 46 7 Using a screwdriver loosen the front welch plug snap ring FIGURE 47 8 Remove snap ring and welch plug from shoulder ASM 0168 S20BZ128 1 Axle Service Manual d 4 m O A D z A w V a A 2083 te FIGURE 48 9 Press off bearings from bevel gears if necessary Clean and inspect all parts replacing any damaged components Dana Holding Corporation 14 Shoulder Assembly Shoulder Assembly FIGURE 51 3 Install 14T bevel gear and bearing assembly D amp E with snap ring B into shoulder housing NOTE Do not install shims C until backlash measurements are taken 7 FIGURE 49 1 If removed press bearings D amp G onto bevel gears E amp H FIGURE 52 4 Measure end play of the upper shoulder gear To set the end play a Measure distance between the bearing D and the snap ring B at several locations 20 i b Assemble shims C such that end play is within FIGURE 50 0 014 0 017 in 0 36 0 43 mm This will ensure 2 Install 11T bevel gear and bearing assembly G8H backlash is 0
23. tighten to 12 15lbs ft 16 20 Nem Then fill final drive housings and main axle with 3 8L The oil seal L should always be replaced Do not reuse 1 0 ga J20C oil a MIN FIGURE 97 2 Verify the oil level is between the MIN and MAX level on the dipstick FIGURE 94 21 Install spacer K slinger M spacer N amp NEW pin ion nut O Apply Loctite 272 to pinion nut threads and tighten to 75 90 lbs ft 102 122 Nem Avoid Damage Allow oil one hour to settle before checking level to ensure accurate dipstick reading Then repeat oil check after several hours of operation o al U FIGURE 95 22 Install the center housing welch plug cap using the Welch Plug Driver Tools page 36 The welch plug should always be replaced Do not reuse 20 Dana Holding Corporation ASM 0168 S20BZ128 1 Axle Service Manual Tie Rod Installation Tie Rod Installation FIGURE 98 Tie Rod Boots FIGURE 99 1 Inspect tie rod end boots replacing boots as needed 2 Insert tie rod ends into holes in knuckle arms FIGURE 100 3 Install castle nuts to tie rod ends and tighten to 74 85 lbs ft 100 115 Nem 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 Axle Installation amp Toe in Adjust ment on page 28 6 Install wheel to final drive 7 Torque the tie rod jam nut to 85 96 Ibs ft 1
Download Pdf Manuals
Related Search