Service Manual
Contents
1. 32 Po eu _ 33 34 35 gt gt gt NNP 35 0204 700 211 Axle Service Manual Dana Holding Corporation Dana Holding Corporation ASM 0204E 700 211 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 guick 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 a2. 32 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual gt 0C 0 N U lt O LLI U la SPECIAL TOOLS OKR 2 7
3. jss senm srs sosum 7 Oni _ 104 1140 1200M _ 1240 MOS mm Ora ara fisn 2rsum 20852506 Wm 2290 2520Nm 2404 2757 Nm FINE PITCH SIZE OF BOLT OF BOLT JO 27 asam fas ssnm frs seenm _ fss sisnm s52 6Nm s menm m sNm _ _ 90 10Nm i istnm rosita je sim fein fis semi 169 T7EN fis senm er wonm aozenn _ fez ssnm oer soon _ jez senm I ers ssum oro errum _ Sm senm je senm fral sienm 1140 126 1985M Moorem 2803 Nm 2582577 N 798 0204 700 211 Dana Holding Corporation 9 TORQUE SPECIFICATIONS WHEEL TIGHTENING TORQUES Wheel nut tightening torques recommen
4. lt gt SPICER Off Highway Products Service Manual 700 211 Axle 5 0204 September 2015 5 _ _ _ 5 MAINTENANCE 8 LUBRICATION I I uu u 7 DEFINITION OF VIEWPOINTS 7 7 _ _ gt 2 _ 8 OF PRE UPE fa 8 UNI OF WEG AE ORA 8 UNITO OF To na 8 ee Ah 9 COARSE PITCH ROR RAA 9 EINE EC g aa 9 WHEEL NUT TIGHTENING TORQUES Ne 10 MAINTENANCE POINTS ee 11 _ lt gt _ 2 _ ___ 12 GREASING FAE QUENCY RAN 12 LUBRICANT 8 SEALANT SPECIFICATIONS ssania 13 SAFETY PRECAUTIONS ________ 15 _ __ _ _ _ 17 EXPLODED 17 a 18 _ 21 TRUNNION a e 25 EXPLODED uu 25 DISA PE NANA 26 _ _ _ __ 26 5 9 27 Pi 27 TROUBLESHOOTING onen GE AE 29 SPECIAL TOOLS nitki R AAA 31 JO 31 _ _ _ 22 32 gt gt gt gt gt gt gt gt
5. THE TORQUE FIGURE ON NUT AND STUD COUPLING MUST RELATED ON STUD MATERIAL QUALITV DANA AXLES 10 9 ONLY 10 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual MAINTENANCE POINTS MAINTENANCE POINTS 1 Grease zerk 0204 700 211 Axle Service Manual Dana Holding Corporation 11 MAINTENANGE INTERVALS MAINTENANCE INTERVALS GREASING FREQUENCV In the axle assembiv four greasing points have been provided at following parts 2 on kingpin 1 no on center pivot tube 1 no on cylinder pin Wheel hub assembly is protected with a cassette seal which is not to be greased externally FOLLOWING GREASING IS RECOMMENDED For Pudding Field Greasing is required to do externally after every 10 hrs of paddy operation at all greasing points For Dry Normal Field Greasing is required to do externally once in 100 hrs of tractor operation at all greasing points Do not take out the hub But if some impurities or improper hub rotation observed then disassemble the wheel hub It should be noted that once hub is removed from wheel end as
6. 14 17 from the axle FIGURE 11 Using special tool T1 see drawing T1 p 31 re move the ring nut 25 FIGURE 8 Using an internal extractor remove the bearing 16 from the axle ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 19 DISASSEMBLY FIGURE 12 Disassemble wheel hub 24 components Outer bearing 28 Inner bearing 29 Seal ring 30 20 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 16 Install the cover in its seat and tighten the cap screws 21 complete with washers 22 to a torque of 9 11 FIGURE 13 Using a press and suitable tools see drawings N m 2 32 and p 32 install wheel hub 24 components Outer bearing 28 Inner bearing 29 Seal ring 30 FIGURE 17 Using special tool T6 see drawing T6 p 35 in stall the bushings in their seats FIGURE 14 Install the ring nut 25 and using the special tool I 1 see drawing T1 31 tighten to a torque of 50 70 N m FIGURE 18 Using special tool T7 see drawing T7 p 35 in stall the seal rings 14 17 in their seats Anabond 676 FIGURE 15 Spread the cover with Anabond sealant 676 or eguivalent ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 21 ASSEMBLY FIGURE 19 Install the bearing 16 in its seat FIGURE 22 Check vertical gap using a lever King pin Preload Draw 0 1 0 3 mm First step
7. shim Measured Backlash Preload Draw Example First step Shim 2 5 mm Measured Backlash 1 mm S 2 5 mm 1 mm 0 2 mm 1 3 S 1 3 mm FIGURE 20 Prepare a series of shims 13 of 2 5 mm to be assembled under the locker FIGURE 23 Insert the tie rod pins in the steering knuckle 20 and lock nuts 9 into position using a torque of 120 130 N m FIGURE 21 Install the steering knuckle 20 Install the spacer 13 and the locker 12 Tighten the screw 11 to a torque of 180 220 N m Pay attention not to damage the sealing rings FIGURE 24 Install the two spacers 8 and the two seals 6 Fit the steering cvlinder 2 into its seat 22 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual ASSEMBLY FIGURE 25 Install the steering cylinder pin 6 and tigten the capscrew 4 to a torque of 25 N m Install the snap ring 3 in its seat Personal injury can result when removing snap ring The appropriate safety equipment must be worn avoid injury to your eyes wear protective glasses during this procedure 120 135 FIGURE 26 Insert the cvlinder rod in the steering knuckle 20 and lock nuts 9 into position using a torque of 120 135 N m ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 23 24 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual TRUNNION EXPLODED VIEW ASM 0204E 700 211 Axle Ser
8. Dana Holding Corporation 15 16 Dana Holding Corporation 0204 700 211 Axle Service Manual STEERING KNUCKLE EXPLODED VIEW ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 17 DISASSEMBLY DISASSEMBLY FIGURE 3 Loosen and remove the grease zerk Remove the snap ring 3 the capscrew 4 and the steering cylinder pin 6 Personal injury can result when removing snap ring The appropriate safety eguipment must be worn To avoid injury to your eyes wear protective glasses during this procedure FIGURE 2 Disconnect the tapered pins of the cylinder 2 from the steering knuckle using a suitable diameter driver FIGURE 4 Extract the cylinder 2 using a plastic hammer Remove the two spacers 8 and the two seals 6 FIGURE 5 Remove the tie rod nuts 9 Disconnect the tapered pins of the tie rod 10 using a puller 18 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual DISASSEMBLY FIGURE 6 Loosen and remove the hex screw 11 complete FIGURE 9 Using an internal extractor remove the bushings with locker 12 and spacer 13 from the axle Remove the complete steering knuckle 20 Removing the capscrew 11 the steering case could come out from its seat support the steering knuckle 20 with su itable lifting device FIGURE 10 Loosen and remove the screws 21 and the co ver 23 FIGURE 7 Using an internal extractor remove the seal rings
9. Holding Corporation ASM 0204E 700 211 Axle Service Manual MAINTENANCE amp LUBRICATION DEFINITION OF VIEWPOINTS LEFT SIDE RIGHT SIDE LATO SINISTRO LATO DESTRO LINKE SEITE mw RECHTE SEITE LADO IZQUIERDO LADO DERECHO COTE GAUCHE COTE DROITE DATA PLATE 1 Model number 2 Serial number 3 Axle number ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 7 CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE oco 8 Dana Holding Corporation 0204 700 211 Axle Service Manual TORQUE SPECIFICATIONS SPECIFICATIONS COARSE PITCH SIZE OF BOLT OF BOLT rors moxtmm 05 145 167 fis wanm 181 20Nm _ maxiasmm 256 284M orz srann Simm 200 281Nm 21 Ram 00 221m ero enm oo Sati or atsiri 2 PAN KA ae sten KARTON 900 451 Nm azs aoum s3 Oni _ e60 70Nm
10. and tighten the jam nuts to 85 96 16 ft 200 220 ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 27 28 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual TROUBLESHOOTING SNO CONDITION POSSIBLE CAUSES REMEDV Wheel Hub bearing preload not cor rect Check the preload bearing condition Bearing failure Oil seal failure Excessive Wheel Wobbling als Excessive king radial play kingpin bottom Excessive plav in drop arm Adjust the endplav Center tube thrust washer worn out Replace the thrust washer Hitting Noise from front axle sup port Excessive play in center tube bushes Replace the bush and seals worn out bushes 3 Hitting noise from kingpin side Excessive axial float in king pin tube S SOD enw acne oh required thickness Ball joint failure Replace the ball joints 4 Incorrect Steering function NOTE If in doubt please contact authorized person for more details and clarifications Continuous improvement is always a part of process please refer proper documents for better results ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 29 30 Dana Holding Corporation 0204 700 211 Axle Service Manual SPECIAL TOOLS T2
11. bricants 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 countrv where the axles are being overhauled 9 Make sure that 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 friendiv solvents 10 For the sake of claritv the parts that do not normally need to be removed have not been reproduced in some of the diagrams 11 For agricultural the terms RIGHT and LEFT refer to the position from the operator s seat For construc tion axles the terms RIGHT and LEFT refer to the position outside facing the machine with the input drive facing forward 12 After repair work has been completed accuratelv touch up anv coated part that mav have been damaged 13 Follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle Indicates an imminentiv hazardous situation which if not DANGER avoided will result in death or serious injurv Indicates an imminentiv hazardous situation which if not avoided could result in death or serious injurv Indicates a situation which if not avoided mav result in damage to components Indicates information which may make product service ASM 0204E 700 211 Service Manual
12. ded from rim s O E M with reference to the qualitv of the rim s material WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL OUALITY ST 37 ST 52 WHEEL NUTS WITH M18 x 1 5 mm 330 N m 460 N m INTEGRATE IE 22 1 5 630 740 FLAT COLLAR WHEEL 18 1 5 270 360 N m NUTS WITH SEPARATE SPHERICAL LOCK 20 1 5 360 450 WASHER 22 x 1 5 mm 460 N m 550 WHEEL NUTS WITH IN 18 1 5 260 360 N m TEGRATE SEAT CAPTIVE WASHER sl M20x1 5mm 350 N m 500 N m M22 x 1 5 mm 450 650 MATERIAL ST 52 IS RECOMMENDED BY DANA AXLE APPLICATIONS IT IS THE OPTIMUM MA TERIAL FOR TIGHTENING THE RIM TO THE HUB NOTE The wheel nut tightening torque is related on nut thread and stud thread drv without oil or anv lubricant NOTE The wheel nut tightening torque takes into consideration not oniv the nut stud characteristics but also the qualitv of the rim material THE DANA OFFICIAL TIGHTENING TORQUE TABLE INCLUDED IN SERVICE MANUAL SHOWS THE TORQUE FIGURE RELA TO THE BOLT CHARACTERISTIC ONLV DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITV 8 8 amp 10 9 STUD MATERIAL QUALITV 10 9 TORQUE RANGE M18x1 5mm M18 x 1 5 Nem 442 489 M20 x 1 5 mm M20 x 1 5 613 677 Nm 22 1 5 M22 x 1 5 822 908 N m
13. dvisable to use proper eguip 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 the oil it is best to thoroughly clean the unit removing any en crusted or accumulated grease INTRODUCTORY REMARKS 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 reguires the replacement of the other one During assembly the prescribed pre loading backlash and torgue of parts must be maintained SPECIFIC AND SPARE PARTS The drawings of all specific tools reguired for maintenance and repair work can be found the end of this manual spare parts be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorized Distributors of Dana Holding ASM 0204E 700 211 Axle Service Manual Dana Holding Corporation 5 Dana
14. faces with a maximum diametrical clearance of 0 25 mm LOCTITE 512 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 cvlindrical unions up to M80 Before using it remove anv lubricant with the specific activator After polymerisation disassembly may result rather difficult so heating may be 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 fluid
15. s Used when freguent adjusting is reguired 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 0204 700 211 Axle Service Manual Dana Holding Corporation 13 14 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual SAFETV 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 safetv 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 correctiv po sitioned and that the machine is locked lengthwavs 4 not admit any other person inside the work area mark off the area hang warning signs and remove the igni tion kev from the machine 5 Use only clean qualitv tools discard all worn damaged lowguality or improvised wrenches and tools Ensure that all torque wrenches have been checked and calibrated 6 Alwavs wear gloves and non slip rubber shoes when performing repair work 7 Should vou stain a surface with oil remove marks straight awav 8 Dispose of all lu
16. sembiv cassette seal must be replaced with the new cassette seal as it gets damaged once disassembled Also once kingpin seals are removed from their position they get damaged while removing amp hence thev must be replaced 12 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual LUBRICANT SEALANT SPECIFICATIONS LUBRICANT amp 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 tvpical applications of each single material in order to facilitate replacement with similar products marketed 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 completelv remove anv lubricant bv using the specific activator LOCTITE 243 The oleocompatible alternative to 242 Does not require the activation of lubricated surfaces LOCTITE 270 Anaerobic product for verv high strength locking of screws and nuts Before using it completelv remove anv lubricant bv using the specific activator To remove parts it mav be necessarv to heat them at 80 approximatelv 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 sur
17. vice Manual Dana Holding Corporation 25 DISASSEMBLY DISASSEMBLY ASSEMBLY FIGURE 1 Using a screwdriver remove the seal rings 1 4 FIGURE 3 Using special tool T4 see drawing T4 p 33 in from their seats stall the bushings 2 3 Be careful to not damage the seats A X 2 2 3 FIGURE 4 Using special tool 5 see drawing T5 p 34 in stall the sealing rings 1 4 FIGURE 2 Using an internal extractor remove the bushings 2 3 from their seats Assemble in correct position Be careful to not damage the seats 26 Dana Holding Corporation ASM 0204E 700 211 Axle Service Manual TOE IN ADJUSTMENT 1 Supporting the axle with hoist and install axle into vehicle Install front wheels NOTE The toe in adjustment must be performed on the vehicle 2 Jack up front axle so tires are off floor 3 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 4 Measure and record the distance between the lines at the front and the rear of the tire at about axle height The front mea surement should be less than the rear measurement 5 If measurement is not correct loosen jam nuts both ends of tie rod and turn the tie rod using a wrench to increase decrease the amount of toe until the measured dimension is 0 0 125 in 0 2 mm between the front and rear 6 Loctite 262
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