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1. 4 4 1 0 8 EO Ti E zi P1 B B1 2 22 2 1 Oil filling plug P1 Connector for negative brake 2 Oil draining plug P2 Connector for hydraulic service brake 3 Check level plug B1 Bleeding screw for negative brake 4 Release screw for negative brake B2 Bleeding screw for hydraulic service brake 5 Breather ASM OOOGE 114 Axle Service Manual Dana Holding Corporation 11 MAINTENANCE POINTS AXLE MODEL WITH SERVICE BRAKE 1 2 4 12 3 Oil filling plug P2 Connector for hydraulic service brake Oil draining plug B2 Bleeding screw for hydraulic service brake Check level plug Breather Dana Holding Corporation ASM OOOGE 114 Axle Service Manual OIL DRAINING MANDATORY PROCEDURE OIL DRAINING MANDATORY PROCEDURE Do not attempt any maintenance if the axle is hot 40 50 104 122 F Hot and components can cause personal in jury Avoid skin contact Wear protective gloves and glasses e Make sure all fluids are contained during inspection maintenance tests ad
2. ax Sm eer snm jez senm fral sienm 1045 1156 Td use Moorem 2582577 Nm ASM 0006E 114 Axle Service Manual Dana Holding Corporation 9 TORQUE SPECIFICATIONS WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended from rim s O E M with reference to the quality of the rim s material WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS ILLUSTRATION WHEEL STUD THREAD RIM MATERIAL QUALITY ST 37 ST 52 18 1 5 mm 330 460 WHEEL NUTS WITH Em INTEGRATED 2 M20X1 5 mm 490 630 SPHERICAL COLLAR M22X1 5 mm 630 N m 740 N m FLAT COLLAR WHEEL M18X1 5 mm 270 360 NUTS WITH SEPARATE ml x M20X1 5 mm 360 450 N m WASHER M22X1 5 mm 460 N m 550 N m M18X1 5 mm 260 N m 360 WHEEL NUTS WITH INTEGRATE SEAT 20 1 5 mm 350 500 WASHER UN 22 1 5 450 650 RIM S MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS IT IS THE OPTIMUM 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 consideratio
3. g80f7 93096 042 8 30H7 M24x1 5 285 055 689 FILETTARE M74x2 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 75 SPECIAL TOOLS 910 04 4584 A 0 01 _ 190 0 01 113 7700 Al 0 01 68 TRATTO 50 8d8 050 808 037 7 70H7 n6 080 0 01 020 7 0 01 0 01 j 115 65 100 37j7 M20x1 5 76 Dana Holding Corporation 0006 114 Axle Service Manual SPECIAL TOOLS T4 P N 910 04 4588 060 7 7 048 60H7 u7 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 77 SPECIAL TOOLS T5 P N 910 04 4591 0120 7 11 3 0110 ge VISTA DA A A WIEW FROM A A 3x15 gt I 70 N POSIZIONI 0111 1 78 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SPECIAL TOOLS T6 P N 910 04 459
4. 55 62 Dana Holding Corporation ASM 0006E 114 Axle Service Manual BEVEL EXPLODED VIEW 63 Dana Holding Corporation Manu ASM 0006E 114 Axle Service DISASSEMBLY DISASSEMBLY FIGURE 3 Remove the complete arms and the differential unit For details see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p 39 and SERVICE BRAKE p 33 FIGURE 1 Install a double joint lifting eye size M16 connect to a suitable lifting gear and tighten The approximate weight of the unit is 150 kg 331 Ib fastening nuts from the reduction unit T FIGURE 4 Tighten two safety M20 studs in the main body Loosen and remove the capscrews 6 of intermediate cover 4 For details see DIFFERENTIAL p 51 FIGURE 2 Disjoin the entire reduction unit 9 from the axle and place it on a bench FIGURE 5 FLANGED REDUCER VERSION ONLY Using an extractor for ball bearings remove the external re duction unit bearing from the central box 64 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the snap ring 2 FIGURE 8 Extract the pinion 10 complete with the internal bearing cone 9 the spacer 6 and shims 8 NOTE Take care not to bend the snap ring 2 NOTE The bearing cups of the bearing cones remain in the cen tral body Removal of the snap rings can cause personal injuries You must wear appropria
5. Move the bearing cone to the limit stop by hammering lightly all around the edge If assembly is difficult use a driver with a suitable diame ter to seat it FIGURE 32 Install the security flange 9 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 25 ASSEMBLY FIGURE 36 Insert the planetary gears 5 into the cover 3 FIGURE 33 Tighten nuts 7 in two stages using the criss x i Lock gears 5 into position by installing the snap rings cross method Standard nuts 214 236 N m Loctite 243 Flanged nuts 270 300 N m Driloc NOTE Personal injury can result when installing snap ring The ap Check the continuous rolling torque on the hub Torque propriate safety equipment must be worn To avoid injury to 15 64 Nm your eyes wear protective glasses during this procedure FIGURE 34 Install a new o ring 15 on the centering diame ter of wheel hub Lubricate the o ring before fitting FIGURE 38 Fit the planetary carrier cover 3 onto the hub 16 1 FIGURE 35 NOT PRESENT ON ALL MODELS Grease the spacer 27 assemble on the satellite gear 5 as NCAUTION shown in the figure Accurately check the orientation Check that the o ring is in good condition and in position 26 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY FIGURE 39 Lock the planetary carrier cover 3 by tightening the screws 2 Torque wrench setting for screws 40 50 N m
6. The first brake disc 3 to be inserted must be of steel ma NCAUTION den 9 Use only new screws pre treated with Driloc locking adhe ive Threads must be cleaned from oil Y ddl second disc Degrease only non pre treated threads 4 4 FIGURE 18 The second brake disc 2 to be inserted must be of friction material FIGURE 16 Grease sealing face A of axle shaft NOTE Be very careful not to damage the snap ring FIGURE 19 Install the flange 4 on the arm ASM 0006E 114 Axle Service Manual Dana Holding Corporation 37 ASSEMBLY grease 42 5 NC 52 2 FIGURE 20 Insert the end plate 1 Before installing the last FIGURE 23 The arm was attached to a sling during disman brake disc and the end plate 1 spread grease over the con tling tact surfaces to hold them in position while mounting on the The approximate weight of the arm complete with brakes and central housing planetary reduction gear is 351 kg 774 Ib Check condition and position of the arm s o ring install the complete arm 2 NOTE To assist axle shaft centering slightly move the wheel hub Loctite 243 rn i 4 FIGURE 21 Install the end plate 1 with the oil passage notch A facing downwards FIGURE 24 Temporarily lock the arm with nuts previously coated with Loctite 243 tighten lightly to make the unit touch the main body 550 6
7. lt gt SPICER Off Highway Products Service Manual Axle 114 5 0006 July 2015 5 NR DIN 5 SPECIFICATIONS se 7 DEFINITION OF VIEWPOINTS seseettetette tnter tette tette tette tte 7 A ac sus EU ID ML M D KU M 7 CONVERSION TABLES e 8 Mee NN E ME 8 ME 8 MENE 8 TEEN ee 9 COARSE PITCH 9 MEIN 9 WHEEL NUT TIGHTENING TORQUES 10 MAINTENANGE 11 MAINTENANCE POINTS 11 AXLE MODEL WITH SERVICE BRAKE AND NEGATIVE PARKING BRAKE 11 AXLE MODEL WITH SERVICE BRAKE ild 12 OIL DRAINING MANDATORY PROCEDURE 13 CENIDA SING Z PE LUDUM ENN 13 PLANETARY GEAR REDUCTION La a 13 MAINTENANCE INTERVALS cetera saath aa fa seat UM Um UR E dE 14 LUBRICANT amp SEALANT SPECIFICATIONS sseetettettette tentent tette tte tentent 15 SAFETY PRECAUTIONS 17 PEANETARY REDUCTION u 222 19 FEN 19 SE Ne 20 Se EN 24 EE de 29 AR 29 pA EA S D 2 30 31 S 32 SERVICE BRAKE a 33 EXPLODED m 33 34 SAR 36 SERVICE BRAKE AND NEGATIVE PARKING BRAKE I
8. 23 into position while locking the nuts 22 af ter locking check the distance of screws 23 once more Tighten maximum by one turn 40 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY DISASSEMBLY 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 Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 13 A r k FIGURE 7 Insert and tighten two double joint lifting eyes size M16 Connect to suitable lifting gear and tighten The appro ximate weight of the unit is 150 kg 831 Ib Remove fastening screws from the reduction unit FIGURE 8 Disjoin the entire reduction unit from the axle and place it on a bench ASM 0006E 114 Axle Service Manual FIGURE 9 Connect an external pump to the union piece P1 of the negative brake and introduce a pressure of 30 35 bar to eliminate the pressure of the Belleville washers 1 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 NOTE Perform all operations on both arms Remove the oil plug A an
9. Oil seal ring lips and install flange 3 Apply Loctite 242 to the threaded part of the pinion 4 Insert o ring the nut and tighten it using a torque wrench Torque wrench setting 280 310 0006 114 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P N 910 38 4819 STAMPIGL N DISEGNO 151 5 ZZZZ7r 22227772 z 4 2 POSIZIONI 180 MJ S N 88 110 63 5H7 MAT ACCIAIO 41CrAIMo7 BONIFICATO R 90 110 NITRURATO HRC62 65 3 POSIZIONI Y 2 AT ACCIAIO ORI M12 N 3 POSIZIONI 2 POSIZIONI 12 58 RICAVARE DA FLANGIA 114 04 014 01 SALDARE CON ELETTRODI UTP65 2 POSIZIONI A 90 21 lt lt RK MONTARE A CALDO 200 STAMPIGL 660 38 4815 A MAT ALLUMINIO ANTICORODAL SCANALATO INTERNO INNER SPLINE N48x1 25x9H DIN5480 NUMERO DENTI TEETH NUMBER 7 37 MODULO NORMALE NORMAL MODULE m 1 25 ANGOLO DI PRESSIONE PRESSION ANGLE 30 MONTARE A CALDO T 200 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 73 SPECIAL TOOLS T2 P N 910 04 4583 0102 0100 N 3 POSIZIONI A 120 74 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SPECIAL TOOLS 910 04 4583 259 51 10 5 Sez A A
10. chatter noise reduce oil change intervals accordingly In case of extremely low ambient temperatures lt 20 C use appropriate oils w low viscosity UTTO J20 D std Bevel Gears SAE 75W 90 API GL5 LS Hypoid Bevel Gears models 192 193 194 API GL5 To MIL L 2105 B See PSB 00279 latest update for more info regarding lubricants and viscosity grades FREQUENCY whs Monthly 1000 whs Every 500 whs Every 200 whs Normal work Weekly or Severe duty Daily LUBRICANTS For details see below Central body standard bevel gears UTTO API GL4 or gear J20 C MF M1148 or gear SAE80W 90 API GL4 GL5 Central body hypoid bevel gears SAE80W 90 API GL5 REMARKS Clean carefully oil plug magnet If with limited slip differential and or wet brakes use LS additivated oils Clean carefully oil plug magnet UTTO API GL4 J20 C or gear SAE80W 90 API GL4 GL5 Clean carefully oil plug magnet Gears with wet discs clutch ATF GM Dexron IIE Dexron Only gears UTTO J20 C or gear SAE80W 90 API GL4 GL5 For hydraulic actuations brakes SAHR 100 diff lock etc use ATF oil e g GM Dexron IIE Dexron No lubricant allowed 2 EP or NLGI3 EP Clean carefully oil plug magnet in accordance with Machine Service requirements Not applicable NLGI2 or NLGI3 EP with Moly Addittive DOT brake fluids oils are NOT comp
11. the pinion 10 Lock the wrench T1B and rotate the pinion using a torque wrench up to a minimum required torque set ting of 900 N m FIGURE 29 Oil seal ring lips Fit the pinion spacers S1 8 and spacer 6 the main body 1 1 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 69 ASSEMBLY FIGURE 35 Using plug of suitable diameter fit the external FIGURE 33 Apply onto the pinion 10 the bar hold T4 See reduction unit bearing 1 in the central box drawing T4 p 77 and with the help of a torque meter check the torque of the pinion 10 Tightening Torque 2 3 3 2 N m Personal injury can result when installing snap ring The ap propriate safety equipment must be worn To avoid injury to your eyes wear protective glasses during this procedure If torque exceeds the maximum value then the size of shim 51 7 between the bearing cone 8 and the spacer 6 eds to be increased If torque does not reach the set value increase the torque setting of the ring nut 3 in different stages to obtain ma ximum value of 1000 N m If torque does not reach the mi nimum value then the size of shim S1 7 needs to be reduced FIGURE 36 Re install the differential unit and the intermedia te cover lt X FIGURE 34 Insert the snap ring 2 If the crown has been replaced reinstate clearances For details see DIFFERENTIAL p 51 70 Dana Holding Corporation ASM 0006
12. 24 Attach a suitable sling to the brake cover con nect to lifting gear and tighten The approximate weight of the brake cover is 45kg 9915 Remove the studs the brake cover 17 44 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 29 Using a plastic hammer install the piston 3 into the cylinder 17 NOTE Lightly hammer all around the edge in an alternate se quence FIGURE 27 Fit o ring 2 and 4 and anti extrusion ring 18 onto the piston 8 T 7 ox LAT 17 E dn w FIGURE 30 Fit o ring 27 and anti extrusion ring 26 onto the piston 25 FIGURE 28 Check the position of the anti extrusion 18 and o rings 2 and 4 Lubricate the piston and the o rings and install the unit 3 into the cylinder 17 FIGURE 31 The o rings always have to be assembled from the pressure facing side ASM 0006E 114 Axle Service Manual Dana Holding Corporation 45 ASSEMBLY FIGURE 32 Lubricate the piston and the o rings and install FIGURE 35 Install the new o ring the unit 25 into the cover 17 Grease before installing FIGURE 33 Using plastic hammer install the piston 25 FIGURE 36 Position the Belleville washers 1 and engage into the cover 17 the cylinder Spread grease over the contact surfaces to hold them in position NOTE Lightly hammer all around the edge in an alternat
13. FIGURE 42 Insert the end plate Before installing the last bra ke disc and the end plate spread grease over the contact surfaces to hold them in position while mounting on the cen tral housing FIGURE 40 Grease sealing face A of axle shaft 19 Install the axle shaft 19 making sure it is properly engaged in the 1 6 FIGURE 43 Install the end plate 27 with the passage NOTE notch A facing downwards Be very careful not to damage the seal ring 21 FIGURE 44 Check the condition and position of the cover s FIGURE 41 1 Insert the brake discs 24 25 in the right se o ring quence orient them so that the oil circulation holes and the marks B are perfectly lined up 2 Install the flange 26 on the arm NOTE The first brake disc 3 to be inserted must be of steel material ASM 0006E 114 Axle Service Manual Dana Holding Corporation 27 ASSEMBLY Loctite 243 550 600 N m 47 47 wa FIGURE 45 The arm was attached to a sling during disman tling The approximate weight of the arm complete with brakes and planetary reduction gear is 351kg 7741b Install the complete arm Apply Loctite 243 to the threads of the screws 3 and tighten to a torque of 550 600 FIGURE 46 Install the oil level plug 1 Torque wrench setting for screws 30 50 N m 28 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SPECIAL TOOL
14. and fit them in the arm following the correct sequence Orient them so the oil circulation holes and the marks B are per fectiv lined up FIGURE 51 Install the flange 13 on the arm ASM 0006E 114 Axle Service Manual ASSEMBLY FIGURE 52 Insert the brake discs 11 and 12 in the right se quence Spread grease over the contact surfaces to hold them in position while mounting on the central housing NOTE The last brake disc to be inserted must be of steel mate rial 9 FIGURE 53 The arm was attached to a sling during disman tling The approximate weight of the arm complete with brakes and planetary reduction gear is 351 kg 774 Ib Check condition and position of the arm s o ring Install the complete arm NOTE To assist axle shaft centering slightly move the wheel hub Dana Holding Corporation 49 ASSEMBLY FIGURE 54 Temporarily lock the arm with nuts previously FIGURE 56 Gradually release the pressure in the braking cir coated with Loctite 243 tighten lightly to make the unit touch cuit bringing it to zero through the external pump the main body 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 ski
15. 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 Dana Holding ASM 0006E 114 Axle Service Manual Dana Holding Corporation 5 6 Dana Holding Corporation ASM OOOGE 114 Axle Service Manual SPECIFICATIONS DEFINITION OF VIEWPOINTS PSP SPP SISTI 052525252 0 2 2 y a 2 85 ATT AAD Fl IF 7 d ju LI RIGHT SIDE LEFT SIDE LATO DESTRO 7 LATO SINISTRO RECHTE SEITE LINKE SEITE LADO DERECHO LADO IZQUIERDO COTE DROITE COTE GAUCHE DATA PLATE 1 and model unit modification index 2 Serial number 3 Lubricant ASM 0006E 114 Axle Service Manual Dana Holding Corporation 7 CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE i we _ 8 Dana Holding Corporation ASM 0006E 114 Axle Service Manual TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT worse gt 55 0 08 115 18 1878 fis wanm 162 V7ENm_ 161 20
16. gear Standard clearance 0 30 0 40 mm L 54 11 FIGURE 37 Adjusting clearance between pinion and ring ge ar To INCREASE loosen the ring nut on ring gear side and tighten the ring nut on non ring gear side by the same mea sure To DECREASE perform the same operations inversely To rotate ring nuts use special wrench T1 See drawing T1 p 61 0006 114 Axle Service Manual ASSEMBLY FIGURE 38 Using a plug of suitable diameter fit the external FIGURE 40 Using pliers install the cap 14 with the snap reduction unit bearing to the central box ring 13 23 8 26 2 y y 7 Personal injury can result when installing snap ring 47 62 propriate safety equipment must be worn To avoid injury to E your eyes wear protective glasses during this procedure FIGURE 39 Install the screw into the hole and tighten to a torque wrench setting of 23 8 26 2 N m NCAUTION a Use only new screws pre treated with locking adhesive FIGURE 41 The arm was attached to a sling during disman tling The approximate weight of the arm complete with brakes and planetary reduction gear is 351 kg 774 Ib 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 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 59 ASSEMBLY Locti
17. gear side a gt did MMM FIGURE 2 Only if needing removing or adjusting mark the position of the ring nuts 1 Remove the capscrews 3 from the ring nuts 1 FIGURE 5 Disjoin the cover 7 ring gear side 52 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY V 1 p A he gt r gt r 4 L j cM r FIGURE 9 Remove the snap ring 13 and the cap 14 Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to eyes wear eye protection equipment FIGURE 7 Insert an adequately keyed bar in the differential Connect the bar to suitable lifting gear The approximate weight of the differential complete with crown wheel is 60 kg 132 Ib With the help of a bar extract the complete differential unit 28 FIGURE 10 If the bearings need replacing extract the exter nal thrust blocks of the bearings 4 from middle cover 7 NOTE Inspect the o ring 9 3 N J 4 3 ZI f gt T d On v 4 Ls FIGURE 8 Tighten two safety M20 studs in the main body Loosen and remove the intermediate cover 4 screws 6 FIGURE 11 If the bearing needs replacing extract the bea rings 4 from the differential carrier 28 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 5
18. uuu u u 39 T a gt 39 NR 40 ADJUSTMENT 40 EE 41 LOI US A 45 DIFFERENT AEE 51 Fe 51 MANN 52 Ke SE SEE EE 55 Te NN 61 FN 61 EN 62 ASM 0006E 114 Axle Service Manual Dana Holding Corporation BEVEL PINION i 63 EXPLODPED IE NN 63 DISASSEM B NNI TR 64 ASSEMBE gu 67 SEAL RING REPLAGEMENT saa 72 DISASSEMBLY se 72 ASSE trem 72 SPECIAL TOOLS mm 73 Tree le 73 a Roue T INI Sul MEI 74 ME MI tM it E A EA 76 E EE e pr TE A 77 78 ome e ren 79 T rc REMITENTE ushu 80 4 Dana Holding Corporation ASM 0006E 114 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 illus
19. 0 4 PEZZIN 4 PIECES SPINA 12m6x50 DIN 6325 DOWEL 12m6x50 DIN 6325 NOILISOd t INOIZISOd CHIAVE A BUSSOLA MOMENTO T2 24 SALDARE CON ELETTRODI UTP65 10H11 ASM OOOGE 114 Axle Service Manual Dana Holding Corporation 79 SPECIAL TOOLS T7 P N 910 04 4586 80 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASM 0006E 114 Axle Service Manual Dana Holding Corporation 81
20. 00 N m 1 FIGURE 22 Install the new o ring Lubricate before installing FIGURE 25 Secure in position with the screws 3 tightening to a torque of 550 600 38 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SERVICE BRAKE AND NEGATIVE PARKING BRAKE EXPLODED VIEW 39 Dana Holding Corporation 114 Axle Service Manual ASM 0006E RELEASE RELEASE ADJUSTMENT Tecno Lube 101 ee 1 k rest this went Xa 17 y l PSP Ri 1 T m r FIGURE 4 Remove screws complete with nuts and seals Replace seals apply silicone based Tecno Lube 101 grease to the screws and install all parts into the arm FIGURE 1 Loosen nuts 22 of screws 23 provided for the mechanical and manual release of the braking units then move the nuts backwards by approximately 8 mm 34 mm _ m A FIGURE 2 Tighten screws 23 to fasten the pressure plate i 16 9 TP FIGURE 5 Adjust screws 23 to obtain a distance of 34 mm in relation to the arm ans mi md E wes FIGURE 3 Using a wrench tighten the screws 23 in an al ternate sequence by 1 4 turn at a time so as to compress the Belleville washers 1 and disengage the braking disks FIGURE 6 Lock into position with nuts 22 Hold screws
21. 3 DISASSEMBLY T FIGURE 13 Remove the screws 27 joining the differential FIGURE 16 Remove shafts 24 complete with planetary ge unit half box ars 26 and spherical shoulder washers 23 NOTE Mark the coupling marks FIGURE 17 Extract from the differential unit 17 the 2nd pla netary gear 25 s ET Remove the 2nd clutch pack 29 and shim set 19 FIGURE 14 Remove the upper half box 26 and remove the clutch pack 29 NCAUTION If the clutch pack does not need replacing avoid swapping If the clutch pack does not need replacing avoid swapping discs position 54 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 18 Insert the planetary gear 25 and the whole fric tion unit 29 FIGURE 19 Install the planetary gears 26 and spherical shoulder washers 25 onto the bolts 24 Install the planetary gear set tion unit 29 ASM 0006E 114 Axle Service Manual The match marks on the two half boxes must correspond Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads 71 5 785 FIGURE 22 Fit the complete differential unit in a vice and tighten the screws 27 holding the two half boxes together to a torque of 71 5 78 5 N m NCAUTION Tighten screws using the criss cross method
22. Dana Holding Corporation 55 ASSEMBLY FIGURE 23 Mount the ring gear 18 and fasten it to the dif FIGURE 25 Position the differential unit under press and ferential with screws 16 using driver with an adequate diameter install the first bea ring 4 Turn the unit upside down and install the second bearing 4 Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads Pay particular attention position shim with adequate dia meter in order to engage the internal ring of bearing without engaging the cage FIGURE 24 Lock the ring gear 6 by tightening the screws 4 to a torque of 139 154 FIGURE 26 Only if bearings are replaced insert the thrust blocks of the bearings 4 into the intermediate covers 7 NCAUTION Use the criss cross method FIGURE 27 Install the new o ring Lubricate before installing 56 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY FIGURE 28 Install the intermediate cover 7 the opposite side of the ring gears lock cover with screws 6 Tighten screws to a torque of 129 143 N m NCAUTION Use only new screws pre treated with locking adhesive FIGURE 32 Only if ring nuts have been removed tighten the ring nut 3 on ring gear side until clearances between pinion and ring gear are zeroed Then loosen by about 1 4 turn FIGURE 29 Position the di
23. E 114 Axle Service Manual ASSEMBLY FIGURE 37 Re install the arms FIGURE 40 Assemble the reduction unit onto the axle Fa For details see SERVICE BRAKE p 33 and SERVICE BRAKE sten the support planes turn flange to assist assembly AND NEGATIVE PARKING BRAKE p 39 Insert nuts by applying Loctite 243 and tighten to 129 143 N m p FIGURE 39 The reduction unit was attached to a sling during dismantling The approximate weight of the reduction unit is 150 kg 330 Ib Install the entire reduction unit ASM 0006E 114 Axle Service Manual Dana Holding Corporation 71 SEAL RING REPLACEMENT SEAL RING REPLACEMENT DISASSEMBLY ONLY WHEN REPLACEMENT IS NECESSARY Remove the pinion seal ring following these instruc tions 1 If disassembly is difficult heat the check nut of the flange at 80 C NOTE Heating is meant to loosen the setting of Loctite on the nut 2 Loosen and remove the nut also remove the o ring 3 Remove the flange complete with guard 4 Remove the sealing ring If the pinion the bearings or other parts must be repla ced refer to the procedure BEVEL PINION p 63 and DIFFERENTIAL p 51 72 Dana Holding Corporation ASSEMBLY ONLY IF PREVIOUSLY DISASSEMBLED If the pinion the bearings or other components must be installed and adjusted refer to the procedure BEVEL PINION p 63 and DIFFERENTIAL p 51 1 Fit the new seal ring in the main body 2
24. NM 20 enm oaz renn 37 4088 monn _ resten moren parem an nuNm 58 kim x0 rnm a onm kim 2 __ Noe Nm 48 ae stem 0x25 mm _ 900 451 Nm 48 jes senm srs sosum jew senm Merom rcm AD essem 1579 1925 N 20852806 Wm 2807 2404 2757 Nm SIZE OF BOLT TYPE OF BOLT 1 7 snm 28 3058 _ 25mm fss sienm 15 7888 w TeNm een fein usnm vann er onm mecum 58 2 ooe osann oer sonm jiz aenm fiss senm oer sonm er sonm oro errum era
25. S SPECIAL TOOLS T1 P N 910 04 4591 Q AK LO M y 15 N 2 3i 9150 ano 4 30 0006 114 Dana Holding Corporation 29 SPECIAL TOOLS 2 910 06 4592 9208 270 0 08 0 12 040 020 018 i Il 219 N 014506 E 18H11 24H11 NI 82 LER Fs Q s LI acc LO 9 48 Belli HE 8 O 145H7 45 158 2 0164 518 0 3 2194 87 56 25 30 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SPECIAL TOOLS 910 06 4594 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 31 SPECIAL TOOLS T4 P N 910 04 4595 084 070 LO x OD LO st 7 90 G SG st CN 750 LO 040 0 2 0 049 5 070 069 5 971774 32 Dana Holding Corporation 0006 114 Axle Service Manual SERVICE BRAKE EXPLODED VIEW 33 Dana Holding Corporation 114 Axle Service Manual ASM 0006E DISASSEMBLY DISASSEMBLY Before maintaining brakes when the axle is installed on the vehicle follow all safety instructions in the Or
26. arts 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 sc
27. at ible w std oils Check for any damage or corrosion of treads or mating surfaces Supply grease until clean grease is vis ible from outside Grease performance level acc to Ac cording to DIN 51825 level KP2K 30 NLGI2 or 20 NLGI3 ASTM D4950 NLGI2 GC LB Dana Holding Corporation ASM OOOGE 114 Axle Service Manual 14 LUBRICANT amp 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 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 p
28. d drain oil FIGURE 10 If axle is positioned on an overhaul bench place a safety anti tilting stand B under the arm that remains con nected and block wheels if any Dana Holding Corporation 41 DISASSEMBLY FIGURE 11 Attach a suitable sling to the arm connect to lif FIGURE 14 Gradually release the pressure in the braking cir ting gear and tighten The approximate weight of the arm cuit bringing it to zero through the external pump complete with brakes and planetary gears is 351 kg 774 Ib 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 DANGER Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake FIGURE 13 Remove arm together with brakes and axle shafts Set the arm in a vertical position using suitable bra ckets to keep it locked in a safe condition 42 Dana Holding Corporation 0006 114 Axle Service Manual DISASSEMBLY FIGURE 16 Remove braking discs 11 12 noting direction of assembly NOTE If disks are not to be replaced avoid changing their
29. e se NOTE quence Check the direction of Belleville washers 1 and relative centering FIGURE 34 Assemble the bleed valve 5 and the new o ring Grease before installing FIGURE 37 Connect suitable sling to the satellite carrier cover connect to lifting gear and tighten The approximate weight of the cover is 67kg 14816 Tighten two safety M20 studs in the main body Engage the cover 17 46 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY FIGURE 38 Insert the screws 29 and tighten them alterna tely Tightening the screws 29 to a torque of 129 143 N m Remove the studs FIGURE 39 Insert the stroke automatic regulation springs 15 place them in line with the intermediate disc 19 FIGURE 40 Insert the intermediate disc 19 ASM 0006E 114 Axle Service Manual 30 35 Bar FIGURE 41 Connect an external pump to the negative brake P1 and introduce pressure to 30 35 bar 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 Driloc FIGURE 42 Fit the reversal springs 9 and screws 10 on the intermediate disk 16 Tighten with torque wrench setting of 15 20 N m NCAUTION Use only new screws pre treated with Driloc l
30. e the crown wheel 11 from the hub 16 NOTE Remove the crown 11 Write down the direction of assembly of the spacer FIGURE 11 Tighten fully into the hole provided a double joint lifting eye size M12 connect to a suitable lifting gear and ten sion The approximate weight of the hub is 42kg 92 5lb With the help of a hammer shift the hub 16 and the external bearing 14 FIGURE 8 Loosen and remove the nuts 7 from the crown flange 1 1 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 21 DISASSEMBLY FIGURE 13 Remove the seal ring 18 from the hub 16 NOTE Write down direction of assembly NCAUTION The seal ring may not be reused FIGURE 14 Remove the internal bearing 18 22 Dana Holding Corporation FIGURE 15 Remove the external thrust blocks of bearings 14 and 17 using a pin driver NOTE Hammer in an alternate sequence to prevent clamping and deformation of the thrust blocks FIGURE 16 ONLY NEGATIVE BRAKE VERSION Connect an external pump to the union piece P1 of the ne gative brake and introduce a pressure of 30 35 bar to elimi nate the pressure of the Belleville washers Hot oil and components can cause personal injury Avoid skin contact NOTE Perform all operations on both arms Remove the oil plug and drain oil 0006 114 Axle Service Manual DISASSEMBLY FIGURE 17 lf axle is positioned on an overhaul bench
31. fferential unit 28 in the central body with the help of a bar and install the middle cover FIGURE 33 Only if ring nuts have been removed preload be arings with ring nut 3 on non ring gear side in order to incre ase the torque of the pinion d FIGURE 30 Tighten the two safety screws C into the main body 11 and install the intermediate cover 7 NCAUTION In the case of used bearings check thrust torque in the case of new bearings check continuous torque ASM 0006E 114 Axle Service Manual Dana Holding Corporation of ASSEMBLY 3 FIGURE 34 FLANGED REDUCER VERSION ONLY Using an extractor for ball bearings remove the external re duction unit bearing from the central box FIGURE 35 Apply onto the pinion 10 the bar hold T2 See drawing T2 p 62 and with the help of a torque meter and check that torque will increase by 0 5 1 0 as result of differential bearing preload Example pinion torque 2 3 3 2 N m Pinion differential torque 2 8 4 2 N m 58 Dana Holding Corporation FIGURE 36 Introduce a dial indicator with long tracer through the hole provided for the cap Position the tracer on the side of a tooth of the ring gear approximately 5 mm from the outer rim preload by about 1 mm and zero the compara tor As you hold the pinion in position move the ring gear manual ly in both directions to check clearance between pinion and ring
32. g T4 p 32 install the rings into the arm NCAUTION Pay particular attention to the direction of assembly of the rings 24 Dana Holding Corporation FIGURE 25 Position the wheel hub 16 under a press Lubricate the seat of the bearing cones 14 17 and using tool T1 See drawing T1 p 29 install the bearing cup of the bearing cone 14 17 FIGURE 26 Fit the bearing 17 and seal ring 18 into the in ternal thrust block A 5 1 4 raj E E 0 FIGURE 27 Apply a joining compound for seals to the outer surface of the sealing ring 18 Position the sealing ring 18 in the hub 16 NOTE Verify the ring 18 is correctly oriented 0006 114 Axle Service Manual ASSEMBLY ah FIGURE 28 Position tool T2 See drawing T2 p 30 and press FIGURE 30 Install the external bearing cone 14 the sealing ring 18 into its seat NOTE Using a plastic hammer drive the bearing cone to the li mit stop by lightly hammering around the edge Check the flatness of seal ring FIGURE 31 Fit the complete crown flange 1 1 FIGURE 29 Insert and tighten two doublejoint lifting eyes size M12 Connect to suitable lifting gear and tighten The ap NOTE proximate weight of the hub is 42 kg 92 5 Ib Install the whe In order to fasten the flange 11 use a plastic hammer el hub 16 and alternately hammer on several equidistant points NOTE
33. ier to perform ASM OOOGE 114 Axle Service Manual Dana Holding Corporation 17 18 Dana Holding Corporation ASM 0006E 114 Axle Service Manual PLANETARY REDUCTION EXPLODED VIEW ITEM 27 NOT PRESENT ON ALL MODELS 19 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY DISASSEMBLY NCAUTION Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 13 FIGURE 3 Using two screwdrivers or two levers inserted in the slots provided disjoin the planetary cover 3 away from the wheel hub 16 Remove the cover 3 FIGURE 1 Carry out all operations one wheel side at a time Remove the oil level plug 1 and drain the oil FIGURE 4 Remove the sun gear 6 FIGURE 2 Attach a suitable sling to the satellite carrier cover connect to lifting gear and tighten The approximate weight of the cover is 67kg 148lb Remove the locking screws 2 of planetary cover 3 FIGURE 5 Remove the snap rings 4 of the planetary gears 5 NWARNING Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to eyes wear eye protection equipment 20 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY FIGURE 7 NOT PRESENT ON ALL MODELS FIGURE 10 Using two screwdrivers or two levers inserted in Remove the spacer 27 the slots provided disengag
34. iginal Equip ment Manufacturer OEM manual that came with the vehi cle NCAUTION Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 13 FIGURE 3 Remove arm together with brakes and axle shafts set the arm in a vertical position using suitable brackets to keep it locked in place Perform all operations on both arms Remove the oil plug Release pressure A and drain oil FIGURE 4 Write down the order of assembly and remove the FIGURE 1 If axle is positioned on an overhaul bench place end plate 1 a safety anti tilting stand B under the arm that remains con nected and block wheels if any FIGURE 5 Remove braking tion of assembly 4 discs 2 3 noting down direc FIGURE 2 Attach a suitable sling to the arm connect to lif ting gear and tighten The approximate weight of the arm NOTE complete with brakes and planetary gears is 351 kg 774 Ib Remove the retainer screws If disks are not to be replaced avoid changing their posi tion 34 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the flange 4 complete with the discs Noting down direction of assembly En xw FIGURE 10 Slowly introduce low pressure compressed air FIGURE 7 Remove the axle shaft through the connection member for the service brake in or der to extract the piston 9 NOTE Be very ca
35. justment 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 ASM OOOGE 114 Axle Service Manual Dana Holding Corporation 13 lt gt TT 22 LLI O lt lt lt TT I 22 lt gt MAINTENANCE INTERVALS OPERATION Oil level check Oil Change Adjustment Tightening Greasing COMPARTMENT Differential 1ST CHANGE CHECK whs 100 250 whs max Hub Reduction 100 250 whs max Dropbox if any Negative brake SAHR Service brake Wheel nuts King Pin Tapered Bearings 100 250 whs max Seals King Pin Bushings Trunnion Bushings In case of severe duty half oil change intervals must be applied In case of extreme enviroments
36. n it is necessary to seek immediate medical care FIGURE 55 Secure in position with the screws 3 tightening to a torque of 550 600 N m 4 a E Rc FIGURE 57 Gradually loosen the sleeve and remove NDANGER Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake 50 Dana Holding Corporation ASM 0006E 114 Axle Service Manual DIFFERENTIAL EXPLODED VIEW ASM 0006E 114 Axle Service Manual Dana Holding Corporation 51 DISASSEMBLY DISASSEMBLY NCAUTION Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 13 FIGURE 3 Only if needing removing or adjusting uniformly heat the ring nuts 1 up to a temperature of 80 C Using tool T1 loosen and remove the ring nuts 3 NOTE Accurately remove any trace of sealant from the threads of ring nuts and intermediate covers FIGURE 1 Attach a suitable sling to the arm connect to lif ting gear and tension The approximate weight of the arm complete with brakes and planetary gears is 351 kg 774 Ib Sling the arm to be removed and connect it to a hoist the retainer screws and relative washers For details see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p 39 FIGURE 4 Tighten two safety M20 studs in the main body Loosen and remove the check screws 6 of intermediate co ver 7 on ring
37. n not only the nut stud characteristics but also the quality of the rim material THE DANA OFFICIAL TIGHTENING TORQUE TABLE THAT IS INCLUDED IN EACH SERVICE MANUAL SHOWS THE TORQUE FIGURE RELATED TO THE BOLT CHARACTERISTIC ONLY DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8 8 amp 10 9 STUD MATERIAL QUALITY 10 9 ALLOW TIGHT TORQUE M18 x 1 5 mm M18 x 1 5 N m 442 489 M20 x 1 5 mm M20 x 1 5 N m 613 677 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 10 Dana Holding Corporation ASM 0006E 114 Axle Service Manual MAINTENANCE MAINTENANCE POINTS AXLE MODEL WITH SERVICE BRAKE AND NEGATIVE PARKING BRAKE
38. ocking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads Dana Holding Corporation 47 ASSEMBLY Arm fix measurement 90 5 0 05 mm 7 N Driloc FIGURE 43 Install the adjusting screws 14 on the threads FIGURE 46 Arm fix measurement 90 5 0 05 mm and tighten to 5 7 N m Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads 90 5 v FIGURE 47 Y 1 5 mm brake gap 90 5 mm x y v Thickness of shims to insert under the shim washer Tolerance 0 1 mm EXAMPLE 90 5 mm 30 2 57 5 1 50 1 30 mm FIGURE 44 Take the measurement from the surface of the intermediate disk to the cover sealing surface with 30 35 bar of pressure introduced EXAMPLE X 30 2 mm ey lt FIGURE 48 Grease the shims S 20 assemble in tion on the spacer braking disc 19 then insert them in the arm NOTE Make sure the shims are inserted correctly FIGURE 45 Put the brake disc pack including the shim under a press load with 1000 kg and take the measure V EXAMPLE V 57 5 mm 48 Dana Holding Corporation ASM 0006E 114 Axle Service Manual U FIGURE 49 Install the spacer braking disc 19 with the oil passage notch facing downwards FIGURE 50 Slightiv lubricate the braking disks 11 12
39. of about 3 mm 68 Dana Holding Corporation FIGURE 24 Remove the depth gauge and remove tool and bearing cone kits from the main body Reinstall every part also introducing a spacer 6 the shims 7 between bearing cones 4 9 Tighten the entire pack by hand until a rolling torque is definitely obtained FIGURE 25 Introduce depth gauge in tool See drawing p 76 and measure deviation from the pre vious measurement EXAMPLE H A B 1 4 mm FIGURE 26 Deviation H must be added to a set value of 0 10 mm to obtain the calibrated spacer value S1 7 for in sertion between inner bearing cone 9 and spacer 6 Dimension S1 must be rounded off to the higher 5 100 EXAMPLE 1 1 7 0 1 1 7 ASM 0006E 114 Axle Service Manual ASSEMBLY FIGURE 30 Heat the external bearing cone 9 to a tempera FIGURE 27 Position the internal bearing 9 and the pinion ture of about 212 F 100 and fit it on to the pinion 10 10 under a press force the bearing onto the pinion FIGURE 31 Apply Loctite 270 to the thread of the pinion ring FIGURE 28 Insert spacer 6 and calibrated spacers S1 7 nut 3 and tighten the nut onto the pinion Refer and keep to the positions marked during disassembly 10 calibrated FIGURE 32 Apply special wrench T1B see drawing T1 p 73 to the ring nut 3 and bar hold T1A see drawing T1 p 73 to
40. place a safety anti tilting stand B under the arm that remains con nected and block wheels if any E j EE BA JA I j i s c us m i FIGURE 18 Connect a suitable sling to the arm connect to lifting gear and tighten The approximate weight of the arm complete with brakes and planetary gears is 351kg 77416 FIGURE 19 Loosen and remove the screws 4 that attach the arm 3 to the central body 6 Remove arm together with brakes and axle shafts lay down the arm vertically ASM 0006E 114 Axle Service Manual FIGURE 20 Remove the flange 26 complete with the discs Noting down direction of assembly For details see SERVICE BRAKE AND NEGATIVE PARKING BRAKE p 39 FIGURE 22 Turn the arm over using the lifting gear The arm was attached to the sling during dismantling The approxima te weight of the arm complete with brakes and planetary ge ars is 351 0 7741b Using an extractor remove seal ring 21 and guide ring 20 NOTE Write down the direction of assembly of seal ring Dana Holding Corporation 23 ASSEMBLY ASSEMBLY FIGURE 23 Lubricate and fit the guide ring 20 onto tool T3 See drawing 31 install the rings into the arm ACAUTION Pay particular attention to the direction of assembly of the rings FIGURE 24 Lubricate and fit the seal ring 21 onto tool T4 See drawin
41. posi tion FIGURE 17 Remove the flange 13 complete with the discs noting direction of assembly FIGURE 18 Remove spacer braking discs 19 and shims 20 noting direction of assembly ASM 0006E 114 Axle Service Manual FIGURE 19 Remove the adjusting screws 14 from the counterwasher 16 FIGURE 20 Remove the reversal springs 9 and screws 10 NOTE If the springs 9 are weak or deformed they must be re placed FIGURE 21 Write down the order of assembly and remove the counterwasher 16 Dana Holding Corporation 43 DISASSEMBLY FIGURE 25 Slowly introduce low pressure compressed air through the connection member for the service brake P2 in order to extract the piston 25 NCAUTION Hold the piston 25 back as it may be suddenly ejected and damaged FIGURE 22 Tighten two safety M20 studs in the main body Loosen the capscrews 29 using the criss cross method and remove them I FIGURE 23 Move the cover 17 outwards while supporting the Belleville washers 1 Remove the Belleville washers 1 and write down direction of assembly FIGURE 26 Slowly introduce low pressure compressed air through the connection member for the negative brake P1 in order to extract the piston 3 NCAUTION Hold the piston 3 back as it may be suddenly ejected and damaged Write down the order of assembly E FIGURE
42. reful not to damage the seal ring AC AUTI ON Hold the piston 9 back as it may be suddenly ejected and damaged FIGURE 8 Remove the reversal springs 8 and screws 7 NOTE If the springs 8 are weak or deformed they must be re placed ASM 0006E 114 Axle Service Manual Dana Holding Corporation 35 ASSEMBLY ASSEMBLY um FIGURE 13 Using a plastic hammer install the piston 9 into Ex the arm FIGURE 11 Insert the stroke automatic regulation springs 6 place them in line with the piston 9 NOTE Lightly hammer all around the edge in an alternate se quence 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 FIGURE 14 Fit the adjusting screws 5 the arm Torque wrench setting 5 7 N m NCAUTION Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads f f 7 f 7 2 7 R gt m um 36 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY first disc 15 20 Pe Driloc FIGURE 15 Fit the reversal springs 8 the piston 9 FIGURE 17 Insert the brake discs in the right sequence Tighten with torque wrench setting of 15 20 N m NOTE
43. rews 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 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 15 16 Dana Holding Corporation ASM 0006E 114 Axle Service Manual 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 Equipmen
44. t 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 13 Indicates an imminently hazardous situation DANGER which if not avoided will result in death or se rious injury Indicates an imminently hazardous situation which if not avoided could result in death or se rious injury Indicates a situation which if not avoided may result in damage to components NOTICE Indicates information which may make product service eas
45. te 243 FIGURE 42 Temporarily lock the arm with screws previously coated with Loctite 243 tighten lightly to make the unit touch the main body 550 600 N m FIGURE 43 Secure in position with the screws 3 tightening to a torque of 550 600 N m 60 Dana Holding Corporation ASM 0006E 114 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P N 910 38 4830 VITE M14x40 DIN912 SCATOLA CENTRALE 114 01 001 01 016 04 ATTREZZO 660 38 4830 USCINETTO INA LS 2035 ATTREZZO 660 38 4830 7777 PP N ANS 7 NE SY 7 EM TG gt GHIERA 194 04 001 01 A KT ZA IANN ME 222 Au WH ZI gt lt lt lN 222222 J PPD SHI za ll BAR DN rz Sy N Em 7 lt lt MC Np 21 x 27 WF WW N GABBIA RULLINI S VE CHIAVE BUSSOLA NT F 0 NSS 2 PEZZI DO WIA SSS SS STAMPIGL N DISEGNO MAT ACCIAIO 42 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 61 SPECIAL TOOLS T2 P N 910 04 4588 23 30 m 3x15 3 15 013 7 8 5x30 i NENNEN 048 030 069 ___ __ N wa 4 j 047 809 60H7 u7 60H7 u7
46. te safety equipment To avoid injury to eyes wear eye protection equipment FIGURE 7 Position wrench T1B see drawing T1 p 73 onto the ring nut 3 and apply bar hold T1A see drawing T1 p 73 to the pinion 10 Stop wrench T1B and rotate the pinion so as to release and remove the ring nut 9 NOTE If disassembly is difficult heat the ring nut to approxima tely 212 F 100 C FIGURE 10 Remove the spacer 6 and the calibrated spacer 7 ASM 0006E 114 Axle Service Manual Dana Holding Corporation 65 DISASSEMBLY Fm j FIGURE 11 Using a puller press remove the inner FIGURE 14 Insert a drift in the appropriate holes Remove aring cone 9 from the pinion 10 the bearing cup of the internal bearing cone 9 as well as the shim washers 8 FIGURE 13 Remove sealing ring 5 66 Dana Holding Corporation ASM 0006E 114 Axle Service Manual ASSEMBLY ASSEMBLY s 6 mm calibrated block FIGURE 18 Calculate shims S for insertion under the bea j ring cup of the inner bearing cone using the following formula FIGURE 15 Reset a depth gauge on a calibrated block who S 222 2 I D se known thickness is 6 mm where 222 2 fixed dimension actual pinion center distance D Total bearing thickness EXAMPLE S 222 2 176 9 44 45 0 85 mm FIGURE 16 With a calibrated block on a faceplate allow
47. the bearing cone to set by rotating them in both directions and by applying a vertical thrust position the calibrated block on the external bearing cups Check overall thickness of bearing FIGURE 19 Lubricate the outer surface of the new sealing 44 45 mm ring 5 and fit it onto the main body 11 using tool T5 See drawing T5 p 78 FIGURE 17 Check nominal dimension INT as marked on the pinion Add up to or subtract from the variation in FIGURE 20 Using special tool T2 See drawing T2 p 74 dicated as Y to obtain the actual center distance 7 Partially insert the bearing cup of the bearing cones and EXAMPLE INT Y 177 0 1 176 9 mm shims ASM 0006E 114 Axle Service Manual Dana Holding Corporation 67 ASSEMBLY FIGURE 21 Connect the tension rod to the press and move the bearing cup of bearing cones into the seats Disconnect the press and remove the tension rod NOTE Before starting the next stage make sure the bearing cup has been completely inserted into its seat FW hu ie ue FIGURE 22 CALCULATING PINION BEARINGS ROLLING TORQUE Introduce tool T3 See drawing T3 p 76 complete with bea rings 10 into the central housing tighten by hand to elimina te the axial gap FIGURE 23 Introduce the tracer of a depth gauge DDG into either side hole of tool T3 See drawing T3 p 76 Reset the depth gauge with a preload
48. trating the various phases of the operations allows accurate work 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 ring gear 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 as sembly the sealing rings must be lubricated on the sealing edge In the case of the ring gear and pinion replacement of one

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