Service Manual
Contents
1. isxismm aa MOK Sm aurcm ars ssum oto errum ra Tani necem Ma rismm er oinm oor oo ost rora exem fral sienm 108 156 1140 160 Nm 1258 188 Weine 2108 2360 Nm 2302 2577 Nm 2505 2856 Nm 8 Dana Holding Corporation GSM 0019E 401 Gearbox Service Manual 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 WHEEL NUTS WITH mms M18 x 1 5 mm 330 N m 460 N m INTEGRATE M22 x 1 5 mm 630 N m 740 N m FLAT COLLAR WHEEL M18 x 1 5 mm 270 N m 360 N m NUTS WITH SEPARATE sd TIME ZEN SPHERICAL LOCK d 0x 1 5 mm WASHER m M22 x 1 5 mm 460 N m 550 N m WHEEL NUTS WITH IN E M18 x 1 5 mm 260 N m 360 N m TEGRATE SEAT LIL CAPTIVE WASHER M20 x 1 5 mm 350 N m 500 N m Tis M22 x 1 5 mm 450 N m 650 N m RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS IT IS THE OPTIMUM MA TERIAL FOR TIGHTENING THE RIM TO THE HUB NOTE The wheel nut tightening torque is related only on nut thread and stud thread dry without oil or any lubricant NOTE The whe2. DISASSEMBLV FIGURE 55 Remove the secondary shaft FIGURE 58 Loosen and remove the counternut and lock nut _ 4 a 3 LR Oi 252 EM E m e ATS FIGURE 59 Write down the baffle plate position and remove FIGURE 57 Remove the bearing FIGURE 60 Remove the idler gear 24 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual DISASSEMBLY FIGURE 63 Replace the complete support if the thrust block is damaged GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 25 ASSEMBLY ASSEMBLY Loctite 270 90 100 N m FIGURE 68 Tighten the lock nuts completely FIGURE 65 Spread the screws with Loctite 270 and tighten to a torque of 15 2 16 8 N m FIGURE 69 2nd 3rd gear shaft composition 1 s 2 SE C m 7 LI E cL CR FIGURE 66 Install the spacer Lubricate and fit the roller be aring a 26 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual ASSEMBLY FIGURE 70 Install the secondary shaft FIGURE 73 Using a copper hammer gently tap the bearing to seat it in the case Loctite 243 15 2 16 8 FIGURE 74 Install the mechanical endstops Coat the screws with Loctite 243 and tighten to 15 2 16 8 N m y 1 e e J e e p 4 2 FIGURE 72 Install the spacer and bearing
3. GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 27 ASSEMBLY FIGURE 79 Bend the position stop Do not overlap the folded material a 15724111 KARTA FIGURE 80 Install the gear selector ball and spring Apply the gear selector cap and tightening to a torque of 60 70 N m 1 Loctite 243 48 53 N m FIGURE 78 Install the fork lock nut and tighten to 48 53 N m E 1 Do gt FIGURE 81 Only if removed restore the position of the sup port according to the measurement previously taken Coat threads with Loctite 243 and tighten the nut to a torque of 50 55 N m 28 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual ASSEMBLY FIGURE 85 Insert the input shaft in position FIGURE 84 1st reverse gear shaft composition FIGURE 87 Fit the 2nd gear onto the input shaft GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 29 ASSEMBLY FIGURE 88 Using a copper hammer insert the bearing in po FIGURE 91 Using a copper hammer insert the bearing in po sition sition FIGURE 89 Heat the bearing up to 212 F 100 C and install it onto the input shaft E 2 FIGURE 93 Engage the fork in the coupling FIGURE 90 Lubricate and install the roller bearing 30 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual ASSEMBLY FIGURE 97 Apply LOCTITE 510 to the machined surfa
4. Service Manual Gear Box 401 GSM 0019E June 2014 CONTENTS INTRODUCTION 5 SPECIFICATIONS ssssssssssssessssssssssssssssssssassussatssesaesatsassacsaesseentesesotsaesseeaeeateacsocsaeeatententeocsaeeaeestesteneens 6 DEFINITION OF VIEWPOINTS 6 6 CONVERSION 27 7 TORQUE SPECIFICATIONS 8 COARSE PITCH 8 ce eg MM 8 WHEEL NUT TIGHTENING TORQUES 9 10 MAINTENANCE POINTS 10 MAINTENANCE INTERVALS 11 LUBRICANT amp SEALANT SPECIFICATIONS ooooooooooooooooooooooooooooWooooooo oo 12 SAFETY PRECAUTIONS cssssssssssstssessessesssssesscsscsssssnssnsscsssssssassneesesatestesteneenssatsaeeaeeatenteaeeaeeatesteneens 13 GEARBOX mieg 15 DISASSEMBLY 15 ASSEMBLY ne an aan aa Nana Man sama 26 SPECIAL TOOLS skin Maan ai 37 A 37 37 38 GSM 0019E 401 Gearbox Service Manual Dana Holding Corporation Dana Holding Corporation GSM 0019E 401 Gearbox Service Manual INTRODUCTION The efficiency and continued operation of mechanical units depend on constant correct maintenance and also on efficient repair work should there be a break down or malfunction The instructions contained in this manual have been based on a complete overh
5. 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 clearance 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 phy sical elements Polymerises with non corrosive dampness TECNO LUBE 101 SILICONE BASED GREASE Highly adhesive synthetic grease with silicone compounds added Applied to adjustment screws with hole communicating with oil type fluids Used when frequent adjusting is required MOLIKOTE DOW CORNING Lubricating compound containing molybdenum disulphide used to lubricate articulation pins and to prevent sti cking and oxidation of parts that are not lubrica
6. 9E 401 Gear Box Service Manual Dana Holding Corporation 19 DISASSEMBLV FIGURE 31 Use a driver to remove the seal ring FIGURE 32 Remove the voke capscrew FIGURE 33 Partially extract the control rod and remove the FIGURE 36 Remove the input shaft spacer Then completely remove the control rod E 20 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual DISASSEMBLV FIGURE 39 Position the input shaft under a press and using a suitable drift remove the ball bearing GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 21 DISASSEMBLV gt FIGURE 46 ONLY IF NEEDED Before removing the support check the installation measure ment as shown in picture above Example 30 mm 1 A 71 d A 4 ou FIGURE 47 Loosen and remove the plug Using a magnet remove the spring and the ball B p 4 30 p 1 TTL NS k b Fam FIGURE 45 Remove the gear selector bar FIGURE 48 Remove the caulk from the position stop 22 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual DISASSEMBLY FIGURE 50 Partially extract the eoniiel rod and remove the spacer then completelv remove the control rod M FIGURE 51 Write down the fork position and remove FIGURE 54 Remove the reverse gear as shown above GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 23
7. I 2 GC LB GSM 0019E 401 Gearbox Service Manual Dana Holding Corporation 11 MAINTENANCE 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 repla cement 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 Be fore 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 lubri cant by using the specific activator To remove parts it may be necessary to heat them at 80 C approximately LOCTITE 275 Anaerobic product suitable for high strength locking and sealing of large threaded parts bolts and stud bolts for pipe sealing and for protecting parts against tampering suitable for sealing coupling surfaces with a maximum dia metrical 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
8. aul 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 photographs and diagrams illustrating the various phases of the ope rations allows accurate work to be performed All the information needed for correct disassembly checks and as sembly 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 following operations it is pre sumed 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 pro per equipment 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 encrusted or accumulated grease INTRODUCTORY REMARKS All the disassembled mechanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage wear cracking or seizing have occurred In particular thoroughly check the condition of all moving parts bearings gears crown wheel and pinion shafts and sealing parts O rings oil shields which are sub
9. ces FIGURE 95 Install the fork lock nut and tighten to 48 53 FIGURE 98 Install the spacer onto the output shaft N m Loctite 510 73 81 FIGURE 99 Fit the cover onto the casing and align the pins FIGURE 96 Use special tool T1 see drawing T1 p 37 to in stall the seal ring seating completely N CAUTION Take care not to damage the seal ring NOTE Apply grease to the inner lip of the seal ring GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 31 ASSEMBLY FIGURE 103 Fit the gear selector yoke in position Loctite 243 TAN 90 100 Nim FIGURE 101 Apply the T2 tool see drawing T2 p 37 onto FIGURE 104 Install the lever adjustment pins the flange Secure the wrench and tighten the screw using a torque wrench up to a minimum required torque setting of 90 100 N m Chamfer the stop Do not repeat the chamfer on top of the first chamfer Loctite 573 FIGURE 105 Apply LOCTITE 573 to the machined surfaces and fit the gear selector cover on the housing FIGURE 102 Insert the ball piston and the spring in posi tion 32 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual ASSEMBLY Loctite 573 15 2 16 8 N m Loctite 510 FIGURE 106 Apply and tighten the screws securing the gear FIGURE 109 Coat the surface of the main body with Loctite selector cover with their respective washers 510 and install the supp
10. el nut tightening torque takes into consideration not only the nut stud characteristics but also the quality of the rim material THE DANA OFFICIAL TIGHTENING TORQUE TABLE INCLUDED IN EACH SERVICE MANUAL SHOWS THE TORQUE FIGURE RELA TED TO THE BOLT CHARACTERISTIC ONLY DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8 8 amp 10 9 STUD MATERIAL QUALITY 10 9 TORQUE RANGE M18 x 1 5 mm M18 x 1 5 Nm 442 489 N m M20 x 1 5 mm M20 x 1 5 Nm 613 677 N m M22 x 1 5 mm M22 x 1 5 Nm 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 GSM 0019E 401 Gearbox Service Manual Dana Holding Corporation 9 MAINTENANCE MAINTENANCE MAINTENANCE POINTS 1 Oil fill plug 2 Oil drain plug 3 Check level plug 4 Grease zerk 10 Dana Holding Corporation i GSM 0019E 401 Gearbox Service Manual MAINTENANCE MAINTENANCE INTERVALS OPERATION MEMBER FREQUENCY LUBRICANTS Check levels Monthly Gearbox ATF DEXRONE III Oil change Every 1000 hrs Greasing Clutch fork retainer pin Monthly iate n If working in severe duty conditions half intervals should be used nitially after 100 working hours According to DIN 51825 level KP2K 30 NLGI 2 or KP3K 20 NLGI 3 ASTM D4950 NLG
11. hift rail cover 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 12 Measure and write down shim quantity and po sition Do not switch shim locations NOTE Carefully remove all Loctite residue from surfaces FIGURE 9 Remove the pressure plate fork and stud 16 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual DISASSEMBLY FIGURE 13 Remove the paper gasket FIGURE 16 Using an extractor remove the seal ring FIGURE 15 Remove the sleeve FIGURE 18 Remove the clutch housing GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 17 DISASSEMBLV FIGURE 19 Cut the retainer clip and remove the protective boot and o ring FIGURE 23 Remove the gear selector voke cover together with washers NOTE Carefully remove all Loctite residue from surfaces NOTE Note the position of the control lever before removal E FIGURE 24 Using a magnet remove spring spacer and ball L g al FIGURE 21 Remove the gear selector cover 18 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual DISASSEMBLY FIGURE 25 Lift the caulk from the safety flange then loosen FIGURE 28 Loosen and remove the cover screws and wa and remove the capscrew and washer shers FIGURE 27 Remove the flange FIGURE 30 Remove the spacer GSM 001
12. ice Manual Dana Holding Corporation 7 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT e oo DN rzortoeme zr Weximm 981058 os nswm uscszwm wr nswm Wexiasmm nas mzwm fe sanm mann Jaan marem fis sena 3 1708 5170 8120 mexem __ 200 221Nm a anm Jari jes senm eoo asinn 0 20 mm sa Ori oo eornm 722 708 22x25 mm jss senm srs casum zao 0211 Sm fers rasnm __ 950 1080 im from tson THD 180 Nm Sam 8 jora 2115 Nem 2085 2005 Nm 2200 2520 20a 25r Nm FINE PITCH SIZE OF BOLT TYPE OF BOLT 5 9 Jiosriosiezoji Weximm fear manm fers sisnm fas wanm fas sasnm 25mm fes senm cem eo em 0 25mm s0 T00Nm 8 1 us WeNm 221 1 58 51 58 51118 5 1 51 Mariam _ 200 222Nm eo enm jew zenm ooe osann 88 faer ooon
13. ject to major stress and wear In any case it is advisable to replace the seals every time a component is overhauled or repaired During assembly the sealing rings must be lubricated on the sealing edge In the case of the crown wheel and pinion replacement of one component requires the replacement of the other one During assembly the prescribed pre loading backlash and torque of parts must be maintained CLASSIFICATION This manual classifies units according to part numbers For a correct interpretation classification is indicated as follows bb O up tothe part number O part number on When no classification is given disassembly and assembly operations are the same for all versions 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 GSM 0019E 401 Gearbox Service Manual Dana Holding Corporation 5 SPECIFICATIONS DEFINITION OF VIEWPOINTS n 1 DATA PLATE SIAGIEIR TYPE SERIAL No m RATIO MFG BY DANA ITALIA S P A MADE IN ITALY 1 Unit type 2 Serial number 3 Model number 6 Dana Holding Corporation GSM 0019E 401 Gearbox Service Manual CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE GSM 0019E 401 Gearbox Serv
14. oluol xylolbased 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 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 GSM 0019E 401 Gearbox Service Manual Dana Holding Corporation 13 14 Dana Holding Corporation GSM 0019E 401 Gearbox Service Manual GEARBOX DISASSEMBLY FIGURE 4 Mark the positions of levers in relation to the thrust lever FIGURE 6 Loosen and remove the nut FIGURE 3 Only if necessary remove the grease zerk GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 15 DISASSEMBLY SR OS FIGURE 7 Using a copper hammer gently tap and remove FIGURE 10 Using an extractor for inner parts remove the the conical pin of the yoke bushings A FIGURE 11 Remove the s
15. ort Tighten to a torque of 15 2 16 8 N m NOTE Make sure a continuous layer of sealant runs around the locking holes E 4 5 FIGURE 107 Adjust the lever adjustment pins and reset the gap to zero FIGURE 110 Coat the screw threads with Loctite 510 and tighten to the following torque specifications M8 35 40 N m M10 70 75 Nm FIGURE 111 Using the special tool T3 see drawing T3 p 38 install the seal ring into the sleeve GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 33 ASSEMBLY AN Loctite 510 2 Erw N m FIGURE 112 Coat the screw threads with Loctite 510 and tighten to a torque of 15 2 16 8 N m FIGURE 113 Restore the shims in the same position and FIGURE 116 Only if removed use a driver to install the bu quantity previously marked shing in its seat FIGURE 114 Install the paper gasket using the marking FIGURE 117 Assembly the pin and pressure plate yoke as made previously as reference previosuly marked 34 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual ASSEMBLY Loctite 243 h 238 26 2 N m FIGURE 118 Install the snap ring FIGURE 121 Install the lever and block with screw and Carefully check snap ring is completely inserted tighten to 23 8 26 2 N m Refer and keep to the positions marked during disassembly Personal injury can result when installing snap ring The appropriate safety equi
16. pment must be worn To avoid injury to your eyes wear protective glasses during this procedure FIGURE 122 Install the grease zerk Torque wrench setting 5 8 FIGURE 123 Install the plug and tighten to 90 N m FIGURE 120 Assemble washer and nut and tighten GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 35 ASSEMBLY FIGURE 124 Add the specified oil through the dipstick thre aded hole to bring the level up to the maximum mark on the dipstick The oil level should be between the maximum and minimum marks on the dipstick 36 Dana Holding Corporation GSM 0019E 401 Gear Box Service Manual SPECIAL TOOLS T1 _ 70 _ 2 N o _ 240 _ 263 u T2 230 X detail X detail 195 15 Z 2 GSM 0019E 401 Gear Box Service Manual Dana Holding Corporation 37 SPECIAL TOOLS T3 268 16 04 1 5x45 38 Dana Holding Corporation 025 15 15 5 032 5 GSM 0019E 401 Gear Box Service Manua
17. ted on a regular basis LITHIUM BASED GREASE Applied to bearings sliding parts and used to lubricate seals or parts during assembly 12 Dana Holding Corporation GSM 0019E 401 Gearbox 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 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 po sitioned 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 igni tion key from the machine 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 Always wear gloves and non slip rubber shoes when performing repair work 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 10 11 12 and dispose of them according to the relative law provisions obtaining in the country where the axles are being overhauled Make sure that only weak solvents are used for cleaning purposes avoid using turpentine dilutants and t
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