Service Manual
Contents
1. STEERING CYLINDER CILINDRO STERZO LEN CILINDRO DEDESVIO CVLINDREDEDIRECTION FIGURE 40 ADJUSTING THE STEERING ANGLE Loosen the nut of one of the adjusting screws on cvlinder si FIGURE 37 TOE IN de If necessarv adjust alignment after loosening the check nuts 11 of ball pins 12 NOTE Perform the same operations on both sides see dia gram STEERING ANGLE ANGOLO DI STERZATURA EINSCHLAGWINKEL ANGULACION DE DESVIO ANGLE DE BRAQUAGE 50 DISTANCE DISTANZA ABSTAND DISTANCIA DISTANCE a FIGURE 38 Hold joints 12A tight and rotate the ball pins 12 H until tools T2 See drawing T2 p 45 become parallel to each M BT other FIGURE 41 Adjust the jutting portion of the screw 15 accor ding to data shown in the table NOTE Lock into position with nut 14 tightened to 145 148 N m 1 Loosen the nuts by a few turns 2 Half a turn of the pin will reduce the front stud by about 3 mm and increase the rear one by about 3 mm ASM 0029E 223 Axle Service Manual Dana Holding Corporation 43 ASSEMBLY FIGURE 42 Perform one full steering operation until the adju sted screw 15 leans against the arm stop FIGURE 43 While holding the adjustment screw in position against the arm stop adjust the screw opposite 16 on non cylinder side until it leans against the arm sto2. III UoJx dq All uoix dq ND JLV u91n 2 SOSIP JOM UM SIEGE Yaubew Bnid uo Ajjnjoreo ue o G15 10 719 Idw 06 MO84VvS roh 10 0 02f 1D Idw OLLN Yaubew pnd uo Ajjnjaseo ue o SIIO PAJBAHIppe S7 osn SOYyBJQ JOM 10 pue leup due Dou YM Ji youbew Enjd Wo Ajjnjoueo UB9JO SMYVINAY 919 Id 06 MO84VS surah jeAoq piod u Apog jeuan G15 10 19 Idv 06 MO84VvS roh JO SY LIN AW O Ozr eab 10 v19 Idv OLLN sveeb I eA q DISDUEIS Apog EJ U9 Moleq 988 S I2 9P 104 SINVDIHAMI Ajieq Ainp 949 99 JO Anom MOM EWON SUM 00Z Alen SUM QOS 439 4 SUM 000L AIURUOW sym AON3nO3tid sBulysng UOILUNIL sBulysng Uld Su sjeaS SUM 00L XBW SUM OGZ 001 s6uueeg pslodej uld bury SINU ee 8YEJQ SIMAS HHVS ep enye6oN Aue JI xogdoug XBW SUM OGG 001 uononp ti qnH XBW SUM OGG 001 SUM MO3HO 39NVHO ISL egua LNAW LBVdWOD Buise io 6ulu luBi lusw snipy BueuO 110 Y92949 949 WC NOILVHHdO 13 Dana Holding Corporation ASM 0029E 223 Axle Service Manual 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 replacem
3. Make sure that the snap ring 1 fits snugly in its seat ET 1 D an FIGURE 23 Check the condition of the axle unit s o rings 9 Grease piston seats with Tecnolube Seal 101 and install cylinder using a plastic hammer Akil E si FIGURE 24 Block cylinder 8 with screws 7 coated with Loctite 242 and tightened to atorgue of 180 200 N m ASM 0029E 223 Axle Service Manual ASSEMBLY fu d NR FIGURE 25 Apply Loctite to the threaded portion of the ste ering bars and connect the bars by tightening the ends in the piston rod Tightening torque 430 470 Nm FIGURE 26 Introduce the pins 3 in the steering cases 5 and lock into position with nuts 2 tightened to a torque of 350 390 N m ASM 0029E 223 Axle Service Manual fe a Fi FIGURE 27 If required install the steering piston stroke cen tering sensor 1 for checking piston centering and tighten screws 13 Tightening torque 5 6 Nm If required eliminate the action of the negative brake FIGURE 28 Apply tools T2 See drawing T2 p 45 onto the wheel hubs and lock tools Check that tools are perfectly flat and parallel to each other using a level B T An _ i aie De j FIGURE 29 Connect the sensor 1 to the control device ac cording to either of the following diagrams Dana Holding Corporation 41 ASSEMBLY Imax 0 80 A CONNETTORE CONNECTOR BATTERIA BATTERY
4. MARRONE BROWN FIGURE 30 Sensor wiring diagram for STANDARD version I max 0 80 A CONNETOR BATTERV 1 N FIGURE 32 Center by slowly moving the piston first in one direction then in the opposite one position the piston in the middle point of the stroke which is determined by the control device signalling lamp turning on and switching off in the re verse stage 42 Dana Holding Corporation FIGURE 33 Check distance C of piston on either of the two sides and write down distance dimension to check subse quent adjustments NOTE For cylinders without sensors piston must be centered based on maximum stroke FIGURE 34 Lay level L on two upper studs and line them up Apply tools T2 See drawing T2 p 45 to the two horizon tal studs hold them in position with two nuts level them and finallv lock into position FIGURE 35 Without moving the piston check front B and rear A using tool T1 See drawing T2 p 45 at R value R 400 mm see picture below ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 39 Once toe in has been adjusted lock nuts 11 FIGURE 36 Adjust the convergence with a difference betwe i Tightening torque for nuts 328 363 N m en A and B of maximum 2 5 mm A B 2 5 mm R 400 mm
5. DISASSEMBLY FIGURE 19 Remove shoulder 22 and first planetary gear 21 ring 7 e p i 4 Chart Gi FIGURE 20 Remove shafts 18 complete with planetary ge FIGURE 23 The differential unit ars 15 19 and spherical shoulder washers 14 20 CA b 24 rs 2 J Z TT ce CHE Ee Sh Shafts 18 17 aw SW spherical shoulder washers 9 13 14 20 P planetary gears 8 21 SR shoulder ring 22 7 S planet wheels 10 12 15 19 23 upper half box OQ PE M U aS memet 5 half box crown side w Pt 4 ID FIGURE 21 Remove shafts 17 complete with planetarv ge ars 10 12 and spherical shoulder washers 9 13 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 73 ASSEMBLY ASSEMBLY FIGURE 27 Install the planetary gear 21 and shoulder ring 22 FIGURE 24 Install the shoulder ring and planetary gear 8 into the halfbox 5 PI NH FIGURE 28 Mount the locking half box 5 onto the half box A 23 FIGURE 25 Install the planetary gears 10 12 and spherical shoulder washers 9 13 onto the shafts 17 Install the planetary set 42 lt e Cel 4 A l KAN 7 DP a z M mg 20 z W ER p A FIGURE 29 Lock the half box with screws 24 coated with Loctite 270 FIGURE 26 ane the aenean gears 15 19 and spherical shoulder washers 14
6. Y i TI 2 S E oo I cO gt 250 H7 2 ki 260 H7 p 6 4 L Y Y 8 2165 A ib _ 2184 8 2200 1003 28 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIAL TOOLS T5 P N 2366 2180 040 MK oo SKS A KKK lt MAKAN SERVES LIIS PK A A 140 gt Se gt gt 8 gt 90 SS gt gt SKN E gt be 20 RK 280 Se o Se IS RR gt gt SO dg QL SES RENE NS gt EE SE SSS 20 e RR e SS 0 QL CLS cy SSK QQ R QL x amp Ge SC SS T OS A XS x SR XX KA be be ses LI A _ Abe 48 10 oai mosz G di 14 6 6 5 gt ES 2140 SC 154 9 2178 2189 0205 T6 P N 2378 m V 100 30 LEO o umli 3X45 1 5 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 29 30 Dana Holding Corporation ASM 0029E 223 Axle Service Manual COMPLETE STEERING CASE EXPLODED VIEW Jul Cen m N JW e On gt 14 S ASM 0029E 223 Axle Service Manual Dana Holding Corporation 31 DISASSEMBLY DISASSEMBLY Before draining oil release the interna
7. Mean sama ASSE NIBE Y Kom aman na Maman RELEASE aaa pa anna uns une ARTE EE DIFFERENTIAL UNIT EXPLODED VIE W u a hias aa sat DISASSEMBLY gasili wiki GA bb anna ASSENIBI EE SPECIAL TOOLS sn ada aa Ea Sn cn laen BEVEL PINION EXPLODED VIEW eomma DISASSEMB ba ea Ea POSE NIE Y as b am adan SPECIAL TOOLS ss ne NS LIMITED SLIP DIFFERENTIAL UNIT EXPLODED VIEW see e DISASSEMBL see nama ASSEMBE see ren ee an SWINGING SUPPORT EXP LO DED VIEW naa c DISASSEMBL A Sut ida ia mun asah POSE MBEY iii iet i GO anti SERVICE BRAKE EXPLODED VIEW zai zed AE EG DISASSEMBLE Y E ASSEMBEY wadia kusen alasan 4 Dana Holding Corporation ASM 0029E 223 Axle Service Manual INTRODUCTION The efficiency and continued operation of mechanical units depend on constant correct maintenance and also on efficient re pair work should there be a break down or malfunction The instructions contained in this manual have been based on a com plete overhaul of the unit However it is up to the mechanic to decide whether or not it is necessary to assemble only individual components when partial repair work is needed The manual provides a quick and sure guide which with the use of photogra phs and diagrams illustrating the various phases of the operations allows accurate work to be performed All the information needed for correct disassembly checks and assembly of each individual component is set out below In order to remove the different
8. ana SPICER Off Highway Products Service Manual Axle 223 ASM 0029E September 2015 CONTENTS INFRODUGTION WEE 5 SPEGIFICATION Sa oa 7 DEFINITION OF VIEWPOINTS nee 7 DATA EE 7 CONV RSION TABLES aa AN 8 UNTO e EE 8 UNIT OF ee i EE 8 UNITS elza poj JP R dd EN Ina 8 TORQUE SPECIFICATIONS sz a a 9 SIE Ee ETC 9 FINE PITO WER 9 WHEEL NUT TIGHTENING TORQUES seen 10 MAINTENANCE EE 11 MAINTENANCE PONS b n n assant ettette tb tbb n nn tnn rnrttdtttteeeeeeeeenns 11 OIL DRAINING MANDATORY PROCEDURE nes 12 CENI ON e 12 PLANETARY GEAR REDUCTION nn st ct tues cents 12 Ma Aa an IR 13 LUBRICANT 8 SEALANT SPECIFICATIONS sens 14 SAFETY PR CAUTIONS Se e ui 15 PLANETARY REDUCTION GEAR see 17 EP ODED VIEW ZA 17 DISA E oa 18 TEE 22 SE ai 26 I NON 26 A 26 Pn sss 27 PR TOW a phausi 28 EE 29 A D D aqa 29 COMPLETE STEERING CASE uwaa a I U i 31 Ao ee ne eae i nn as 31 SSL 32 SCIAN EJB ER AO TP 33 STEERING CYLINDER eee en 35 Ae ee ee eee ee re ne Oe net ee ee eRe rem 35 DISASSEMBLY ere 36 EE ZNACZNE 39 SRE CIA TOOL mata mind ina dit 45 e BEE 45 ENNY 45 UEJOINT e 47 Ab ne Ba 47 DCAS EMD E MANA NAN AA EN NA SAN 48 TEE 49 ADO EE EE 50 KEE 50 EO REECE 50 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 3 BRAKE WEAR CHECK PROCEDURE OLD VERSION E NEW VERSION uyay a EA OE Er SPECIAL TOOLS sda ki Oka i GEE GG OEG ati OGAE SERVICE BRAKE AND NEGATIVE PARKING BRAKE EXPEODED VIEW ne DISASSEMBLE
9. 20 onto the shafts 18 Install the planetary set Loctite 270 1 The match marks on the two half boxes must corre spond 2 Use only new screws 74 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 30 Fit the complete differential unit in a vice and FIGURE 33 Lock the ring gear 6 by tightening the screws 4 tighten the screws 24 holding the two half boxes together to to a torque of 150 N m using the criss cross method a torque of 80 N m Tighten screws using the criss cross method FIGURE 34 INSTALLATION OF THE DIFFERENTIAL UNIT Position the differential unit under a press and using a driver with an adequate diameter install the first bearing 3 FIGURE 35 Turn the unit upside down and install the second bearing 25 FIGURE 32 Mount the ring gear 6 and fasten it to the diffe rential box with screws 4 Pay particular attention position a shim with adequate dia meter in order to engage the internal ring of bearing without engaging the cage Use only new screws ASM 0029E 223 Axle Service Manual Dana Holding Corporation 75 ASSEMBLY FIGURE 36 Only if bearings are replaced insert the thrust FIGURE 39 Position the differential unit in the central body blocks of the bearings into the intermediate covers with the help of a bar and fit the middle cover FIGURE 40 Tighten the two safety screws C into
10. 223 Axle Service Manual DISASSEMBLY Me FIGURE 6 Extract the steering cylinder 8 using a plastic FIGURE 9 Using a punch force the stop ring 4 located in hammer side the cylinder 3 and extract ring using a screwdriver FIGURE 7 Before attempting to disassemble the unit drain FIGURE 10 Using a plastic hammer hammer the piston 5 the oil in the cylinder chambers completely so it strikes against the head 2 Using a screwdriver remove the snap ring 1 of the cylinder Continue until the head 2 is ejected from the cylinder 3 head 2 FIGURE 11 Take the cylinder unit 8 apart by extracting the FIGURE 8 Lightly tap the cylinder head 2 with a plastic head 2 first followed by the piston 5 hammer to push it inside the cylinder 3 NOTE Insert the cylinder head so it is flush with the cylinder Write down direction of installation of piston whose seal ring A is oriented towards cylinder head 2 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 37 DISASSEMBLY FIGURE 12 Remove all seals anti extrusion rings and scra per rings from head 2 cylinder 3 and piston 5 NOTE 1 All seals must be replaced at each disassembly 2 Pay particular attention not to damage seal seats and piston beds 38 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 16 Apply tool T1 See drawing T1 p 45 to the pi ston rod on non
11. 3 to a temperature of about 212 F 100 C and fit it on to the pinion 5 to complete the pack as shown in the figure above NOTE Lightly lubricate bearing 3 with SAE85W90 oil FIGURE 26 Make sure that the bearing 6 is well set ASM 0029E 223 Axle Service Manual Dana Holding Corporation 87 ASSEMBLY FIGURE 30 Install the flange 10 onto the pinion 5 without FIGURE 32 Apply onto the pinion 5 the bar hold and with the sealing ring the help of a torque meter check the torque of the pinion 5 Torque 120 180 N cm Loctite 242 800 1000 N m If torque exceeds the maximum value then the size of cali brated spacer S1 7 between the bearing 6 and the spa cer 8 needs to be increased If torque does not reach the set value increase the torque setting of the ring nut 1 in dif ferent stages to obtain a maximum value of 800 1000 N m If torque does not reach the minimum value then the size of calibrated spacer S1 7 needs to be reduced When calculating the increase or decrease in size of calibra Ierd spacer S1 bear in mind that a variation of calibrated spacer 4 of 0 01 mm corresponds to a variation of 60 N cm FIGURE 31 Apply wrench to the ring nut 1 and bar hold T1 in the torque of the pinion 5 See drawing T1 p 90 to the pinion 5 Lock the wrench T1 See drawing T1 p 90 and rotate the pinion using a torque wrench up to a minimum required torque setting of 800
12. ASM 0029E 223 Axle Service Manual Dana Holding Corporation 21 ASSEMBLY ASSEMBLY FIGURE 23 Install bearing 16 Apply Arexons seal rubber cement to the outer surface of seal FIGURE 20 Fit the bushing 18 in the steering case 3 using ring 15 tool T2 See drawing T2 p 26 Position the seal ring 15 in the hub 7 Check ring orientation carefully FIGURE 21 Apply a coat of AREXONS rubber cement to the outer metal surface of the snap ring 17 Position the seal ring and using tool T3 See drawing T3 p 27 fit it in the appropriate seat FIGURE 24 Position tool T5 See drawing 15 p 29 and press the seal ring 15 into its seat Check direction of installation carefully FIGURE 25 Turn the hub over 7 lubricate bearing seat and using tool T4 See drawing T4 p 28 install the bearing thrust block 8 WT FIGURE 22 Position the wheel hub 7 under a press lubri cate the outer seat of bearing and using tool T4 See drawing T4 p 28 install the thrust block of bearing 16 22 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 26 Fit the flange 14 in the ring gear 13 and lock into position with snap ring 12 NOTE Check that snap ring 12 is fully inserted in the slot of ring gear 13 P of the planetary cover 2 To insert gears use tool T6 See drawing T6 p 29 The radiused part of bearings i
13. DISASSEMBLY if as 3 A C masma FIGURE 4 Gradually release the pressure in the braking cir cuit bringing it to zero through the external pump Do not remove any part of the hydraulic circuit without ha ving completely released the hydraulic pressure The removal of pressurized parts or loss caused from relea sing these components can cause serious injuries and even death A leak from a hole of the size of a pin can cause se rious injury If fluid is injected into the skin it is necessary to seek immediate medical care FIGURE 5 Gradually loosen the sleeve and remove ADANGER Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake ASM 0029E 223 Axle Service Manual FIGURE 6 Remove the adjusting screws counterwasher 23 LI La FIGURE 8 Write down their order of assembly and remove the counterwasher 23 i r d z i 7 A P d K ge i hi j r l M N 1 a ka L k i k Vi k ka e i m 2 d ra PY WN m vt F oy a oe Z B X rs Ge W l N N k j 3 GE Z A Down Dana Holding Corporation 13 from the 57 DISASSEMBLY e Lat QS v FIGURE 9 Loosen the studs in an alternate method and re move them FIGURE 12 Remove the Belleville washers 1 NOTE Check the sense of direct
14. block whose known thickness is 42 mm Preload the gauge by about 3 mm FIGURE 15 Bring inner bearing 6 complete with thrust block under gauge DG EXAMPLE 42 0 5 42 5 D Press the thrust block centrally and carry out several mea surements by rotating the thrust block ASM 0029E 223 Axle Service Manual FIGURE 16 Check nominal dimension I as marked on the pinion Add up to or subtract from 1 the variation indicated as Y to obtain the actual center stud I EXAMPLE 135 0 1 134 9 NOTE M5 Match part number Sal FIGURE 17 Calculate shims S for insertion under the thrust block of the inner bearing using the following formula S 178 I D where 178 fixed dimension I actual pinion center stud D total bearing thickness EXAMPLE S 178 134 9 42 5 0 6 mm Dana Holding Corporation 85 ASSEMBLY NZ d f I in O H W FIGURE 18 Using special tool T3 See drawing T3 p 91 par FIGURE 21 Introduce the tracer of a depth gauge DDG into tially insert the thrust block of the bearings 3 6 and shims 4 either side hole of tool T4 See drawing T4 p 92 Reset the gauge with a preload of about 3 mm FIGURE 19 Connect the tension rod to the press and move pi MSDE the thrust block of bearings 3 6 into the seats FIGURE 22 Remove the gauge and take out tool and bearing Disconnect the press and remove the t
15. 1000 N m FIGURE 33 Make positional marks across nut 1 and pinion 5 tang then remove nut and flange 10 88 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 34 Apply Arexons rubber cement to the outer surfa FIGURE 37 Tighten the nut until the match marks line up ce of the new seal ring 9 and fit ring in the main body 12 using driver T5 See drawing T5 p 93 FIGURE 36 Oil seal ring lips and install flange 10 Mount o ring 11 and apply Loctite 242 to pinion tang tighten nut 1 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 89 SPECIAL TOOLS SPECIAL TOOLS T1 P N 2308 7 185 02 7 34 5302 BE 50 90 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIAL TOOLS T2 P N 2381 T3 P N 2377 ND UT ASM 0029E 223 Axle Service Manual Thrust block Thrust block Differential box Cylinder Dana Holding Corporation 91 SPECIAL TOOLS T4 P N 2374 GLXE IINI i col 92 Dana Holding Corporation ASM 0029E 223 Axle Service Manual I O O lt e 17 A I T5 P N 23 5 125 A Ck A 8S 1 S6L N d El 93 Dana Holding Corporation ASM 0029E 223 Axle Servi
16. 101 RELEASE FIGURE 54 Loosen nuts 30 of screws 31 provided for the mechanical and manual release of the braking units then move the nuts backwards by approximately 8 mm ks z mg Me FIGURE 55 Tighten screws 31 to fasten them onto the pres sure plate 23 i ji i a m a EE 1 ee FIGURE 56 Using a wrench tighten the screws 31 in an al ternate sequence by 1 4 turn at a time so as to compress the Belleville washers and disengage the braking disks Tighten maximum by one turn gt Z K inap FIGURE 57 Remove screws complete with nuts and seals Replace seals apply silicone based Tecno Lube 101 grease WT to the screws and install all parts into the arm b ju l j e FIGURE 58 Adjust screws 31 to obtain a distance of 34 0 5 mm between axle machined surface and screw underhead FIGURE 59 Lock into position with nuts 30 Hold screws 31 into position while locking the nuts 30 af ter locking check the distance of screws 31 once more ASM 0029E 223 Axle Service Manual Dana Holding Corporation 67 68 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DIFFERENTIAL UNIT EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 69 DISASSEMBLY DISASSEMBLY FIGURE 4 Only if removing or adjusting use special tool T1 See drawing T1 p 79 to mark the position
17. 20Nm mexiasmm fes mana fas manm fa senm s67405Nm s0 10Nm o7 wan Moxismm enz Taas ams ena aan Ten wegen aam emm Tess 200 281Nm aer Rat emer DEE 909 941 Nm eor sron _ S7I AION M826 mm oam aam _ s00 481Nm fes senm ae Tee 0x25 mm _ 900 451 Nm Teams seoor nm fes sernm _ e60 7Nm emer 22x25 mm jes senm Tome rees Terence on vena enen Ierzen Teams Tears row sou TO T2EOW ran tarowm MSO mm 1781625 en eens iora 2115 Nm 2082505 Wm Teens 2408 2757 m FINE PITCH SIZE OF BOLT TYPE OF BOLT mensen nn artes aro mn erte 1 erte wm far manm fas ssnm fe wanm iozu Lesen Iessen _ IMiOx 25mm fs sisnm Tarzan rs menm Teens ena Teens wer s0 100Nm _ et tosNm Te Tam emer emer ween eens eens Tas aeren eisen ito atm antam fumeur ST Wani ez jewrzznm jes zsnm amour DEELER DEELER EEESCHE Mos Sm Tam Tore Jo OTT im _ 674 TANm Teams Tee ax Sm Ia senm eor TON im jez senm oo oosit fss nesna foa nenm Wegen fral sienm Tse mens Ad TABGN Terrens 1961807 m DEER ASM 0029E 223 Axle Service Manual Dana Holding Corporation 9 WHEEL NUT TIGHTENING TORQUES WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended 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 QUALITY ST 37 ST 52 WHEEL NUTS WITH i M18 x 1 5 mm 330 N m 460 N m
18. Axle Service Manual ASSEMBLY FIGURE 37 Lock the planetary cover 2 with screws 1 Tightening torque for screws 40 50 N m ASM 0029E 223 Axle Service Manual Dana Holding Corporation 25 U O O I lt e LLI A I SPECIAL TOOLS TI 225 260 205 27 w gt 25 55 p 3x45 120 P N 2364 046 259 061 8 R1 5 2x49 T2 P N 3348 30 S20 T 3115 200 35 40 250 GW 0 090 0 GID GLO ASM 0029E 223 Axle Service Manual Dana Holding Corporation 26 SPECIAL TOOLS T3 P N 2365 32 2 Z s 2 zl ai 8 S SIS SS e Q OOO ON C gt C C SIN A 3x15 rl 3x15 L 6 355 21 14 Lg 219 ji 250 ii D1240330 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 27 SPECIAL TOOLS 47 631 T4 P N 3265 2184 l 240 235 os aj p Z BI ong o Sei LO A Y Y go 178 sj 245 CO bl Ne 0 8
19. ON NB j i IS T Ek A p w jii 8 Hh 4 TA _OHTH DEL ZALICZA A ISIL PRZEZ rr TU 1 Oil filling plug 2 Oil draining plug 3 Check level plug 4 Check brake disc wear Minimum thickness between counter discs is 5 2 mm NOTE For details see BRAKE WEAR CHECK PROCEDURE p 51 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 11 OIL DRAINING MANDATORV PROCEDURE OIL DRAINING MANDATORV PROCEDURE e Do not attempt any maintenance if the axle is hot 40 50 C 104 122 F Hot oil and components can cause personal in jurv Avoid skin contact Wear protective gloves and glasses e Make sure all fluids are contained during inspection maintenance tests adjustment and repair of the product Prepare a suitable container to collect the fluid before removing any component containing fluids Dispose of all fluids following legal and local regulations CENTRAL HOUSING Before draining oil it is mandatory to loosen the oil filling plug or the breather if present and wait until the internal pressure is completely released Remove the oil draining plug and drain oil only when the pressure is completely released PLANETARY GEAR REDUCTION Before draining oil it is mandatory to rotate the planetary gear reduction in order to move the oil plug in filling position then loosen the oil plug and
20. screws 35 50 N m Dana Holding Corporation 53 SPECIAL TOOLS SPECIAL TOOLS TI 54 Dana Holding Corporation SE SN ki i O O n 21 BD KB g ASM 0029E 223 Axle Service Manual SERVICE BRAKE AND NEGATIVE PARKING BRAKE EXPLODED VIEW 55 Dana Holding Corporation ASM 0029E 223 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 FIGURE 1 Connect an external pump to the union piece P 1 of the negative brake and introduce a pressure of 21 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 56 Dana Holding Corporation l FIGURE 2 Sling the arm to be removed and connect it to a hoist Loosen and remove screws 31 FIGURE 3 Remove arm together with brakes and axle shafts lay down the arm vertically ASM 0029E 223 Axle Service Manual
21. the main body 28 and install the intermediate cover 38 i FIGURE 41 Tighten screws to a torque of 140 N m of ring gears lock cover with screws 35 coated with Loctite 242 Tighten screws to a torque of 140 N m 76 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 42 Only if ring nuts have been removed tighten the ring nut 2 on ring gear side until clearances between pinion and ring gear are zeroed Then loosen by about 1 4 turn RS FIGURE 43 Only if ring nuts have been removed preload be arings with ring nut 26 on non ring gear side in order to in crease the torque of the pinion In the case of used bearings check thrust torque in the case of new bearings check continuous torque FIGURE 44 Apply torque meter TM to pinion nut and check that torque will increase by 20 40 N cm as a result of diffe rential bearing preload Example pinion torque 120 130 N cm Pinion differential torque 140 170 N cm ASM 0029E 223 Axle Service Manual FIGURE 45 Introduce a gauge A 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 gauge FIGURE 46 As you hold the pinion in position move the ring gear manually in both directions to check clearance between pinion and ring gear Standard clearanc
22. wait until the internal pressure is completely released Remove the oil plug and drain oil only when the pressure is completely released 12 Dana Holding Corporation ASM 0029E 223 Axle Service Manual U lt gt QC LLI lt mi e lt lt L lt in lt L gt MAINTENANCE INTERVALS Sopeif AJISOOSIA pue sjuedugny Buipse6ai ozu aow 104 eyepdn Leo 6 7200 gSd 28S d GOLc 1 TIN OL S9v S 19 IdV p61 6L Z6L SISPOLU s ue pD I eA g PIOdAH ST STO Idv 06 MSZ AVS sieo0 18199 pis q 0Z OLLN AUSOODSIA MOI M SjIO ajeudoudde asn 9 0z gt seanjeJadwa Jusigwe Mol Ajawsiyxo JO SL ul ABUIPI1099e SJBAJ9JLI s6ueyo jio sonpeal esiou JAJJBUD SIUBWOJJAU9 SWAIJXO JO 9SB9 U paljdde ag 3snw SJBAJ9JUI sbuevD jio pey Anp aas JO oSEO ul g1 25 ZID IN 0S6rq NISV EID1N OZ MEHM 10 ZID1N OL MEdM I8A8I GZ8 LG NIC 01 Bulpsoo Jy o1 008 janaj 80UELUOJJSd aepaip BPISJNO WOJJ lqi SIA SI 9SB916 ueaj2 jjun se J6 Ajddng sooejins Furet Jo spe 1 JO UOISO1109 Jo a6ewep Aue 104 Y92949 SJIO PIS M eq JEdWOO JON ae SJIO spiny op LOG ajqevijdde JON sjuswasuinbai O9IM8S SUIUDEN UM DULpIOD UI Yaubew Bnid uo Ajjnjaseo ue o SAPPY AJON UUM d SION 10 d ZID IN dd SION 40 dd cID IN pamojje JUEDLIqN ON uoixeq ll UOIX9 ND Bro 110 4ly asn 93e oo HIP 00L HHVS SOXEJQ SUOIJENJOB DIJNBEJPAL 104 G15 10 719 Idw 06 MO84VvS roh 10 9 0GP OLLN SIE86 JUQ
23. INTEGRATE 15 SE 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 D SPHERICAL LOCK m M20 x 1 5 mm 360 N m 450 N m WASHER M22 x 1 5 mm 460 N m 550 N m WHEEL NUTS WITH IN ang M18 x 1 5 mm 260 N m 360 N m TEGRATE SEAT CAPTIVE WASHER U M20 x 1 5 mm 350 N m 500 N m Ying M22 x 1 5 mm 450 N m 650 N m RIM MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATIONS IT IS THE OPTIMUM MA TERIAL FOR TIGHTENING THE RIM TO THE HUB NOTE The wheel nut tightening torque is related only on nut thread and stud thread dry Without oil or any lubricant NOTE The wheel nut tightening torque takes into consideration not only the nut stud characteristics but also the quality of the rim material THE DANA OFFICIAL TIGHTENING TORQUE TABLE THAT IS INCLUDED IN EACH SERVICE MANUAL SHOWS THE TORQUE FIGURE RELATED TO THE BOLT CHARACTERISTIC ONLY DANA OFFICIAL TIGHTENING TORQUE TABLE NUT MATERIAL QUALITY 8 8 8 10 9 STUD MATERIAL QUALITY 10 9 ALLOW TIGHT TORQUE M18 x 1 5 mm M18 x 1 5 Nem 442 489 Nm M20 x 1 5 mm M20 x 1 5 Nm 613 677 Nm M22 x 1 5 mm M22 x 1 5 Nm 822 908 Nm 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 0029E 223 Axle Service Manual MAINTENANCE MAINTENANCE POINTS Cc eq po Gg H lt im ra BIN EF es ea
24. RAKE WEAR CHECK PROCEDURE OLD VERSION Perform all operations on both arms h FIGURE 1 Remove the oil drain plug and discharge oil FIGURE 2 Apply the parking brake or have someone hold the service brake and with either brake applied check the di stance between discs using tool T1 See drawing T1 p 54 Minimum distance 5 2 mm Replace the braking disks and the intermediate disks on both sides if necessary See SERVICE BRAKE AND NEGA TIVE PARKING BRAKE p 55 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 51 SPECIAL TOOLS FIGURE 3 Checking brake distance with the T1 go no go gauge 35 50 Nem FIGURE 4 Install the oil drain plug Torque wrench setting for screws 35 50 N m Fill with oil 52 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIAL TOOLS NEW VERSION NCAUTION Perform all operations on both arms FIGURE 2 Apply the parking brake or have someone hold the service brake and with either brake applied check the di stance between discs using tool T1 See drawing T1 p 54 Minimum distance 5 2 mm Replace the braking disks and the intermediate disks on both sides if necessarv See SERVICE BRAKE AND NEGA TIVE PARKING BRAKE p 55 FIGURE 3 Checking brake distance with the T1 go no go gauge ASM 0029E 223 Axle Service Manual 35 50 N m FIGURE 4 Install the inspection plug Torque wrench setting for
25. Y ASSEMBLY tt e m ka AW A FIGURE 6 Install the swinging support 4 FIGURE 4 Ifthe bushing 3 is worn and needs replacing wri NOTE te down the assembly side of the connection notch A Check that it is properly oriented Bushing cut position l w FIGURE 7 Install the swinging support 4 on the side oppo site the drive FIGURE 5 Position the swinging support 4 under a press and insert the complete bushing 3 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 103 104 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SERVICE BRAKE EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 105 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 12 a lg r D Ka f 3 Tn L H i Ipda ES f 2 E FIGURE 1 Sling the arm to be removed and connect it to a hoist Loosen and remove screws Differential side Arm side a im FIGURE 2 Write down the order of assembly and remo
26. ation ASM 0029E 223 Axle Service Manual ASSEMBLY Loctite 242 30 35 N m j ka N i 2 Loctite 242 200 221 Nm FIGURE 48 Apply Loctite 242 to the studs and tighten to 30 FIGURE 51 Tighten the nuts in two stages to 200 221 Nm 35 N m L DA bk 1 L ie N AN a Wa WE I m i wn m Kg wn FIGURE 52 Gradually release the pressure in the braking cir FIGURE 49 Check integrity and position of the cylinder s o cuit bringing it to zero through the external pump ring Do not remove any part of the hydraulic circuit without ha ving completely released the hydraulic pressure The removal of pressurized parts or loss caused from relea sing these components can cause serious injuries and even death A leak from a hole of the size of a pin can cause se rious injury If fluid is injected into the skin it is necessary to seek immediate medical care FIGURE 50 Check integrity and position of the arm s o ring install the complete arm NOTE To assist axle shaft centering slightly move the wheel hub ASM 0029E 223 Axle Service Manual Dana Holding Corporation 65 ASSEMBLY FIGURE 53 Gradually loosen the sleeve and remove Carefully check that the hydraulic pressure is discharged completely before removing the external pump sleeve con nected to the brake 66 Dana Holding Corporation ASM 0029E 223 Axle Service Manual RELEASE ADJUST Tecno Lube
27. biv they already respect the predi fined value It is mandatory to install discs of the same material of the original installation FIGURE 10 Fit the clutch pack 11 in the half box When installing the increased shim place shim so that it le ans against the crown wheel 8 10 ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 12 Fit the planetary gear set 9 Mount second planetary gear 8 NOTE Make sure that spherical thrust washers 15 are present FIGURE 13 Fit increased shim 12 clutch pack 7 onto the crown wheel 8 Fit the upper half box 5 and make sure that the match marks line up Complete the assembling operation and install the differential unit following the procedures described in the first part of the manual under section DIFFERENTIAL UNIT p 69 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 99 100 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SWINGING SUPPORT EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 101 DISASSEMBLY DISASSEMBLY Bushing cut position FIGURE 1 Remove the swinging support 4 A AL we FIGURE 2 Remove the swinging MT on the side op posite the drive FIGURE 3 Position the swinging support 4 under a press and remove the complete bushing 3 102 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBL
28. case Position the screws 8 and tighten to 140 Nm Check the correct assembly side of the seal 3 ASM 0029E 223 Axle Service Manual Dana Holding Corporation ER ASSEMBLY e 4 1 x ha Z EW 7 AT Za i c 4 bag FIGURE 11 Using a lever check that there is no vertical gap 30 60 Nm d d sz A d 3 m pm e k FIGURE 12 Check the torque of the pins which has to be between 30 and 60 N m If the preliminary measured value is too high the shims have to be increased 34 Dana Holding Corporation ASM 0029E 223 Axle Service Manual STEERING CYLINDER EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 35 DISASSEMBLY DISASSEMBLY FIGURE 3 Using a puller disconnect the tapered pins of the joints 3 from the steering cases 5 Hin l FIGURE 1 If required remove the steering piston stroke cen tering sensor 1 FIGURE 4 Disconnect left and right steering bars from piston 6 r gg a k L a a H EN NN i ik U 1 Pri RER FIGURE 2 Loosen the check nuts 2 on the joints 3 of the steering bars 4 Remove nuts NOTE Should the joint rotate hold it with a wrench inserted in the seat provided The self locking nuts 2 must be replaced once every 5 dl sassemblies ond Pe J FIGURE 5 Loosen and remove the steering cylinder 8 screws 7 36 Dana Holding Corporation ASM 0029E
29. ce Manual SPECIAL TOOLS 94 Dana Holding Corporation ASM 0029E 223 Axle Service Manual LIMITED SLIP DIFFERENTIAL UNIT EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 95 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 12 FIGURE 3 Make positional match marks on the half boxes of the differential gear 2 loosen and pull out joining screws 4 z FIGURE 1 Remove the whole differential unit 2 from the main body 1 For details see DIFFERENTIAL UNIT p 69 The following section includes clutch replacement procedu res only for gear ring replacement see DIFFERENTIAL FIGURE 4 Remove the upper half box 5 and clutch pack 7 Check and write down the amount of differential discs In function of this quantity deduce the type of material 8 discs friction material PAPER 10 discs friction material MOLY If the clutch pack does not need replacing avoid swapping discs position FIGURE 2 Using a puller remove bearing 3 96 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY If the clutch pack does not need replacing avoid swapping discs position FIGURE 5 Remove the crown wheel 8 and planetary gears set 9 FIGURE 7 Remove the 2nd clutch pack 11 Check and write down the amount of differential discs In function of
30. e 0 25 0 33 mm FIGURE 47 If torque and or pinion ring gear clearance is not within tolerance values and the ring nuts have not been remo ved mark the position of the ring nuts 2 26 and remove the safetv plates 1 27 Dana Holding Corporation 77 ASSEMBLY Wis FIGURE 48 Adjusting clearance between pinion and ring gear To INCREASE loosen the ring nut on ring gear side and tighten the ring nut on non ring gear side by the same measure To DECREASE perform the same operations inversely To ro tate ring nuts use special wrench T1 See drawing T1 p 79 Loctite 242 24 26N m gt s FIGURE 52 Torque wrench setting 283 312 N m NOTE Tighten using the criss cross method FIGURE 49 Engage screw 27 in the slot next to the holes provided for the check screws Coat screws 27 with Loctite 242 and tighten to a torgue of 24 26 Nm 4 FIGURE 50 Fit the top plug after applying repositionable jointing compound for seals to the rims Install the snap ring 78 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P N 2379 x 37H7 n6 SZM lt a 0 3 R ASM 0029E 223 Axle Service Manual Dana Holding Corporation 79 80 Dana Holding Corporation ASM 0029E 223 Axle Service Manual BEVEL PINION EXPLODED VIEW Dana Holding Corporation Manu ASM 0029E 223 Axle Se
31. ension rod kits from the main body Reinstall every part also introducing a spacer between bea NOTE rings 3 and 6 Tighten the entire pack by hand Before starting the next stage make sure that the thrust block has been completely inserted into its seat il FIGURE 23 Introduce depth gauge DDG in tool T4 See drawing T4 p 92 and measure deviation H from the pre vious reset SE CALCULATING PINION BEARINGS ROLLING EXAMPLE H A B 1 8 mm Introduce tool T4 See drawing T4 p 92 complete with bea rings 3 and 6 into the main body 12 tighten by hand until a rolling torque is definitely obtained 86 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ei a EA K FIGURE 24 Deviation H must be added to a set value of FIGURE 27 Refer and keep to the positions marked during 0 12 0 13 mm X to obtain calibrated spacer S1 7 for in disassembiv sertion between inner bearing 6 and spacer 8 Dimension S1 must be rounded off to the higher 5 100 EXAMPLE S1 H X 1 8 0 12 0 13 1 92 1 93 mm mi BMS kn z FIGURE 28 Fit the pinion 5 calibrated spacer S1 7 and spacer 8 in the main body 12 FIGURE 25 Heat the inner bearing 6 to about 212 F 100 C and fit it onto the pinion 5 NOTE Once the bearing has cooled down lightly lubricate bea ring 6 with SAE85W90 oil FIGURE 29 Heat the external bearing
32. ent with similar products marketed by different brand names with different trade marks LOCTITE 242 Anaerobic product apt to prevent the loosening of screws nuts and plugs Used for medium strength locking Before using it completely remove any lubricant by using the specific activator LOCTITE 243 The oleocompatible alternative to 242 Does not require the activation of lubricated surfaces LOCTITE 270 Anaerobic product for very high strength locking of screws and nuts Before using it completely remove any lubricant by using the specific activator To remove parts it may be necessary to heat them at 80 C approximately LOCTITE 275 Anaerobic product suitable for high strength locking and sealing of large threaded parts bolts and stud bolts for pipe sealing and for protecting parts against tampering suitable for sealing coupling surfaces with a maximum diametrical clearance of 0 25 mm LOCTITE 510 Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids Can seal clearances between flanges up to 0 2 mm LOCTITE 577 Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80 Before using it remove any lubricant with the specific activator After polymerisation disassembly may result rather difficult so heating may be necessary for larger diameters LOCTITE 638 Anaerobic adhesive for fast and high strength gluing of cylindrical metal joints
33. eproduced in some of the diagrams 11 After repair work has been completed accurately touch up any coated part that may have been damaged 12 Follow all safety instructions in the Original Equipment Manufacturer OEM manual that came with the vehicle 13 Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 12 Indicates an imminently hazardous situation DANGER which if not avoided will result in death or se rious injury Indicates an imminently hazardous situation 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 easier to perform ASM 0029E 223 Axle Service Manual Dana Holding Corporation 15 16 Dana Holding Corporation ASM 0029E 223 Axle Service Manual PLANETARY REDUCTION GEAR EXPLODED VIEW MIE CEE ASM 0029E 223 Axle Service Manual Dana Holding Corporation 17 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 12 FIGURE 4 Loosen and remove the nuts 4 that lock the gear safety flange 5 ZE er d li FIGURE 1 Remove check screws 1 from planetarv cover FIGURE 2 Alternatelv insert a lever in the slots provided and pry to separate the planetarv cover 2 from the
34. f seal ring 48 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 9 Install the bushing 5 snap ring 4 position the o FIGURE 6 Using tools T1 See drawing T1 p 50 and T2 See ring 8 as well drawing T2 p 50 introduce the seal ring 9 and bearing 7 into the bushing 5 NOTE Check direction of installation of seal 9 carefully sa FIGURE 10 Introduce the twin U joint 3 into the arm and lock into position with stud 2 coated with Loctite 242 Tighten stud to a maximum torque of 15 N m FIGURE 11 Apply Loctite 242 to the jutting portion of the stud 2 and tighten nut 1 Tighten nut 1 to a torque of 60 70 N m while holding stud 2 in position FIGURE 8 Install the complete bushing 5 onto the twin u joint and set bushing into position with a plastic hammer Tap around the whole rim ASM 0029E 223 Axle Service Manual Dana Holding Corporation 49 SPECIAL TOOLS SPECIAL TOOLS T1 P N 3342 i 8 100 7 30 ryw 5 Q RQ 833 9 o o OJ b H po b IXI _ L St Zb 014 10 _ 120 8 T2 P N 2301 11545 A DX u 100 BO CHA D BET SLR z l 3x45 L sp _ 130 _ 8 155 8 50 Dana Holding Corporation ASM 0029E 223 Axle Service Manual B
35. head side 2 and center rod into cylinder 3 FIGURE 13 Grease and install the piston rod seal ring 6 and so as to fit it into piston 5 scraper ring 7 into cylinder 3 NOTE Lightly grease seals and cylinder FIGURE 14 Grease and install the piston rod seal ring 6 and scraper ring 7 into the head 2 FIGURE 17 Introduce the piston 5 into the cylinder by ap proximately 150 mm using a plastic hammer FIGURE 15 Prepare piston 5 by fitting it with guide ring 9 magnetic ring 10 o ring 11 and seal 12 a FIGURE 18 Remove tool T1 See drawing T1 p 45 and ap ply it to the opposite side of the piston 5 1 To ease installation lubricate with grease 2 If acentering sensor is not required the magnetic ring 10 can be replaced with an additional guide ring 9 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 39 ASSEMBLY FIGURE 19 Grease the seals of the head 2 slip the head onto the piston and using a plastic hammer introduce head into cylinder 3 NOTE Introduce the head so it is flush with the cylinder FIGURE 20 Introduce the stop ring 4 and ensure that it sets in the seat of cylinder 3 FIGURE 21 Using two screwdrivers or levers force the head until it is seated against the stop ring 4 40 Dana Holding Corporation FIGURE 22 Fit the snap ring 1 of head 2 If necessary force it into the seat with a punch and hammer
36. 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 nub on shaft Can glue together parts with radial clearance below 0 1 mm AREXONS REPOSITIONABLE JOINTING COMPOUND FOR SEALS Solvent based sealing compound for elastic seals drying through evaporation Used for sealing the outer diameter of sealing rings for rotating shafts with outer metal reinforcement SILICONE Semi fluid adhesive material used for sealing and filling and to protect components from environmental and physical elements Polymerises with non corrosive dampness TECNO LUBE 101 SILICONE BASED GREASE Highly adhesive synthetic grease with silicone compounds added Applied to adjustment screws with hole communicating with oil type fluids Used when frequent adjusting is required MOLIKOTE DOW CORNING Lubricating compound containing molybdenum disulphide used to lubricate articulation pins and to prevent sticking and oxi dation of parts that are not lubricated on a regular basis LITHIUM BASED GREASE Applied to bearings sliding parts and used to lubricate seals or parts during assembly 14 Dana Holding Corporation ss ASM 0029E 223 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
37. ial unit from the vehicle the manuals provided by the vehicle manufacturer should be consulted In describing the fol lowing operations it is presumed that the unit has already been removed from the vehicle IMPORTANT In order to facilitate work and protect both working surfaces and operators it is advisable to use proper equip ment such as trestles or supporting benches plastic or copper hammers appropriate levers pullers and specific spanners or wrenches Before going on to disassemble the parts and drain the oil it is best to thoroughly clean the unit removing any en crusted or accumulated grease INTRODUCTORY REMARKS All the disassembled mechanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage wear cracking or seizing have occurred In particular thoroughly check the condition of all moving parts bearings gears crown wheel and pinion shafts and sealing parts o rings oil shields which are subject to major stress and wear In any case it is advisable to replace the seals every time a component is overhauled or repaired During assembly the sealing rings must be lubricated on the sealing edge In the case of the crown wheel and pinion replacement of one component requires the replacement of the other one During assembly the prescribed pre loading backlash and torque of parts must be maintained SPECIFIC EQUIPMENT AND SPARE PARTS The drawings of all specific tools required for
38. install the unit into the arm 14 FIGURE 15 Fit the adjusting screws 5 Torgue wrench setting 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 FIGURE 13 Using a plastic hammer install the piston 9 into the arm 14 NOTE Lightly hammer all around the edge in an alternate se quence ASM 0029E 223 Axle Service Manual Dana Holding Corporation 109 ASSEMBLY fret dec BAR 4 i j e O pF K FIGURE 16 Insert the brake discs in the correct sequence NOTE The first brake disc 2 to be inserted must be of metal material second disc FIGURE 17 The second brake disc 3 to be inserted must be of friction material NOTE The last brake disc to be inserted must be of friction ma terial FIGURE 18 Install the flange 4 on the arm 110 Dana Holding Corporation FIGURE 19 Insert the intermediate disk 1 x N N FIGURE 20 Check condition and position of the cylinder s o ring t Loctite 242 L w 200 221 Nm L ag FIGURE 21 Cross tighten the nuts in two stages Torgue wrench setting 200 221 N m ASM 0029E 223 Axle Service Manual ASM 0029E 223 Axle Service Manual Dana Holding Corporation 111
39. ion of washers 1 FIGURE 10 Remove the cylinder 24 FIGURE 13 The o rings 2 must be replaced each time the unit is disassembled FIGURE 11 Remove the centering device 26 in the cylinder FIGURE 14 Slowly introduce low pressure compressed air through the connection member for the service brake P2 in order to extract the piston 1 1 Hold the piston 11 back as it may be suddenly ejected and damaged 58 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY FIGURE 18 Remove the flange 17 complete with the discs 20 19 18 FIGURE 16 Slowly introduce low pressure compressed air through the connection member for the service brake P1 in order to extract the piston 3 Hold the piston 3 back as it may be suddenly ejected and damaged Pak LA T geg FIGURE 19 Remove spacer braking discs 27 and shims 28 noting down direction of assembly NOTE Build a stack of washers and check the measurement FIGURE 17 Remove braking discs 14 15 16 noting down direction of assembly NOTE If disks are not being replaced avoid changing their position ASM 0029E 223 Axle Service Manual Dana Holding Corporation 59 ASSEMBLY ASSEMBLY The o rings always have to be assembled from the pressure facing side FIGURE 22 Fit o ring 9 and anti extrusion ring 10 onto the piston 11 Lubricate the piston and the o
40. l pressure for details see OIL DRAINING MANDATORY PROCEDURE p 12 FIGURE 1 Loosen and remove the capscrews 15 8 from the articulation pin 19 4 FIGURE 2 Remove the bottom articulation 19 pin complete with front sealing ring 10 upper articulation pin under articulation pin 32 Dana Holding Corporation lt lt E mg FIGURE 3 Using two levers remove the top articulation pin 4 complete with front seal 9 and shims 3 Pay attention not to damage the surfaces FIGURE 4 Remove the complete steering case 1 ASM 0029E 223 Axle Service Manual ASSEMBLY ASSEMBLY 4 e L WW l sp FIGURE 5 Lubricate the terminal of the u joint and install the steering case 1 Pay attention not to damage the dust cover rings and the se aling rings RTE e 3 CA Gett Z d mala OR Kz Ken ec Ez PURES 7 b bat A FIGURE 9 Fit the unit 19 in the steering case 1 Position the screws 15 and tighten securely Check for the correct assembly side of the seal 10 FIGURE 6 Prepare a series of shims 3 of 0 85 mm to be as sembled under the upper pin 4 FIGURE 10 Tighten the new capscrews 15 of the top and bottom articulation pins in sequence using the criss cross method Torque wrench setting 140 N m FIGURE 7 Fit a new seal 3 onto the top articulation pin 4 Lubricate and install the unit in the steering
41. maintenance and repair work can be found at the end of this manual spare parts may be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorized Distributors of SPICER ASM 0029E 223 Axle Service Manual Dana Holding Corporation 5 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIFICATIONS DEFINITION OF VIEWPOINTS LEFT SIDE RIGHT SIDE LATO SINISTRO LATO DESTRO LINKE SEITE RECHTE SEITE LADO IZQUIERDO LADO DERECHO COTE GAUCHE LLL COTE DROITE O rA O CO oy In Iii A 7 ma aa H H EE M L LA Aa 4 f COOC e w Sit ES RAT TAN Care NA ZY ll Er mi a s DATA PLATE O MFG BY CLARK HURTH COMPONENTS S P A 38062 Arco Trento MADE IN ITALY 1 Type and model unit modification index 2 Serial number 3 Lubricant ASM 0029E 223 Axle Service Manual Dana Holding Corporation 1 CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE o oo wv Iw Li Iw ee E oos WE E RE s 8 Dana Holding Corporation ASM 0029E 223 Axle Service Manual TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT mensen NOA 88 aime 19 mie mo erte won jos Tosum os nsnm Teen fis wanm fe awm i81
42. negative brake and introduce pressure to 21 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 Negative Brake p gt u Brake 22 place them in line with the piston 29 62 Dana Holding Corporation FIGURE 35 Tighten with torque wrench setting of 10 N m FIGURE 34 Fit the reversal springs 12 13 on the interme diate disk 23 10 15 N m Drilock f ke g F ju tax ii a P w WA SS 4 li 3 i 15 Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads ASM 0029E 223 Axle Service Manual ASSEMBLY FIGURE 36 Y brake gap 0 5mm 1 00mm 1 25mm 1 50mm depending on axle configuration 5 7 N m Drilock e ka AW WITT FIGURE 37 Fit the pin screws Torque wrench setting 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 bise m FE 4 Ki FIGURE 38 Take the measurement from the surface of the intermediate disk to the cover sealing surface with 30 bar of pressure introduced EXAMPLE 29 mm ASM 0029E 223 Axle Service Ma
43. nner ring must face the bot tom of the pin ASM 0029E 223 Axle Service Manual FIGURE 29 Oil the seal ring and bushing Slip the steering case 3 onto the twin u joint and fit the pivot pins and con nect the steering bar For details see PLANETARY REDUCTION GEAR p 17 Loctite 270 Tecnolube 101 FIGURE 30 Only if studs have been removed Apply a coat of Loctite 270 to the fast end of studs 19 and apply Tecno lube 101 to ground nut end tighten studs 19 as far as they will go Dana Holding Corporation 23 ASSEMBLY ia LAN 2 d 1 FIGURE 31 Install the wheel hub 7 onto the steering case 3 DK L FIGURE 32 Install the outer bearing 8 NOTE Push the bearing as far as it will go by tapping with a pla stic hammer all around the rim AP A FIGURE 38 Install the complete ring gear flange 5 NOTE To engage the flange 5 use a plastic hammer and ham mer alternately on several equidistant points 24 Dana Holding Corporation FIGURE 34 Ensure that faces are thoroughly cleaned and then mount the safety flange 6 FIGURE 35 Apply Loctite 242 to the studs and tighten nuts 4 Tighten nuts 4 in two stages using the criss cross method Initial tightening torque 250 N m Final tightening torque 460 465 N m FIGURE 36 Fit the planetarv cover 2 on the wheel hub 7 NCAUTION Check state and position of o ring 11 ASM 0029E 223
44. nual FIGURE 39 Put the brake disc pack including the shim under a press load with 1000 kg and take the measure V EXAMPLE V 42 33 mm FIGURE 40 Arm fix quote 74 mm Y brake gap u S 74mm x y v FIGURE 41 S 74 mm x y v Thickness of shims to insert under the shim washer EXAMPLE 74 mm 29 42 33 1 25 S 1 42 mm Dana Holding Corporation 63 ASSEMBLY w a i JE Y rig l fa Bu 4 s sN F L ili 4 1 A p i h K i a A E u A M P L d w 3 L SE d xi ri j e d 4 i E a 5 d KE kul 1 i Fn ji zw x u a l L H M 1 d 1 4 4 Le N 7 D 1 k is A b h j fi j j b d 1 L A 4 1 s y dil e o l a kA j E w 1 D f b a af 5 k d s s i je 1 G EF gt b lt M i D FIGURE 42 Insert under the shim washer a thickness of FIGURE 45 Install the friction disc 18 on the flange 17 from shims 28 arm side and insert the group on the u joint 18 FIGURE 43 Install the friction disc 18 on the flange 17 from arm side 19 2 DISC FIGURE 44 Install the metal disc 19 on the flange 17 from arm side FIGURE 47 Check the alignment of last disc 14 and flange 17 64 Dana Holding Corpor
45. of the ring nuts 2 and 26 FIGURE 1 Sling the arm to be removed and connect it to a hoist Loosen and remove screws and nuts FIGURE 5 Loosen the stud bolts them 27 2k d xi S L AP o F 4 7 Ei m FIGURE 6 Disjoin the cover 38 33 crown side FIGURE 3 Only if removing or adjusting uniformiv heat the ring nuts up to a temperature of 176 F 80 C 70 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY each A ce lt Ra S g NN z a ak ps FIGURE 11 If the bearings need replacing extract the exter nal thrust blocks of the bearings 3 and 25 from middle co ver 33 38 NOTE Accurately check the o ring 37 36 FIGURE 9 Remove the snap ring 30 g z FIGURE 12 If the bearing needs replacing extract the bea ring 3 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 71 DISASSEMBLY FIGURE 13 If the bearing need replacing extract the bearing FIGURE 16 Remove the screws 24 joining the differential 25 from the differential carrier 23 unit half box FIGURE 17 Using a plastic hammer take the half box 23 5 to pieces NOTE Write down the coupling marks FIGURE 15 Remove the spacer 42 and the ring gear 6 FIGURE 18 Remove the upper half box 23 72 Dana Holding Corporation ASM 0029E 223 Axle Service Manual
46. p The screws 15 and 16 must lean against the respective arm stops all at the same time 44 Dana Holding Corporation ASM 0029E 223 Axle Service Manual SPECIAL TOOLS SPECIAL TOOLS T1 P N 2368 250 956 ib M8x1 25 D 5 42 XI p I 1 11 4 Sei m _T Y lt F O NO m i GE y J 065 1 048 Lie _ T2 P N 2367 PA VR g ei Az LO J sf sus 22 40 g 555 9 kd _ 6 _ y 125 y 125 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 45 46 Dana Holding Corporation ASM 0029E 223 Axle Service Manual U JOINT EXPLODED VIEW ASM 0029E 223 Axle Service Manual Dana Holding Corporation 47 DISASSEMBLY DISASSEMBLY Before draining oil release the internal pressure for details see OIL DRAINING MANDATORY PROCEDURE p 12 FIGURE 4 Place the u joint under a press and remove the complete bushing 5 ir FIGURE 2 Extract the whole twin u joint 3 NOTE If necessary use a plastic hammer or lever to ease ex traction of the twin u joint FIGURE 5 Remove the bearing 7 snap ring 6 Remove the o ring 8 and using a puller for inner parts re move the bearing 7 and seal ring 9 NOTE Write down direction of installation o
47. rings and install the unit into the cylinder 24 FIGURE 20 Check the position of the anti extrusion 4 and o rings 2 25 Lubricate the piston and the o rings and install the unit 3 into the cylinder 24 FIGURE 23 The o rings always have to be assembled from the pressure facing side FIGURE 21 Using a plastic hammer install the piston 3 into the cylinder 24 NOTE Lightly hammer all around the edge in an alternate se quence FIGURE 24 Using a plastic hammer install the piston 11 into the cylinder 24 NOTE Lightly hammer all around the edge in an alternate se quence 60 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY es FIGURE 25 Position the Belleville washers 1 and engage the cylinder 24 NOTE Check the sense of direction of Belleville washers 1 and relative centering z 3 Fa W g FIGURE 27 Check integritv and p ring 2 sition of the cvlinder s o ASM 0029E 223 Axle Service Manual P gt de H bn a va 24 FIGURE 28 Engage the cylinder 24 NOTE Check the sense of direction of washers 1 and relative centering Loctite 242 FIGURE 29 Insert the screws and tighten them alternately Lock the cylinder 30 35 N m 7 ju FIGURE 30 Tightening the studs to a torque of 30 35 N m Dana Holding Corporation 61 ASSEMBLY FIGURE 31 Connect an external pump to the
48. rvice DISASSEMBLY DISASSEMBLY FIGURE 3 Position tool T1 See drawing T1 p 90 so as to avoid pinion rotation Loosen and remove the nut 1 and o ring 11 FIGURE 2 If disassembiv is difficult heat the check nut 1 of the flange 10 to 176 F 80 C NOTE Heat will loosen the setting of Loctite on the nut 1 FIGURE 4 Remove the flange 10 complete with guard 2 82 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY FIGURE 8 Using a puller and a press remove the inner bea ring 5 from the pinion 6 KS FIGURE 6 Apply blocks T2 See drawing T2 p 91 and with the help of a puller extract the pinion 5 complete with the in FIGURE 9 Remove the thrust block of the external bearing ternal bearing 6 the spacer 8 and calibrated spacer 4 7 3 NOTE The thrust blocks of the bearings remain in the central body 12 u 4 FIGURE 10 Insert a drift in the appropriate holes FIGURE 7 Remove spacer 17 and calibrated spacer 7 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 83 DISASSEMBLY P FIGURE 11 Remove the thrust block of the internal bearing 6 as well as the shim washers 4 FIGURE 13 Remove the cap 14 84 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 14 CALCULATING PINION CENTER stud Using a faceplate reset a dial indicator DG on a calibrated
49. steering case 3 FIGURE 6 Remove the complete ring gear flange 5 bv using a puller and applving counter pressure to the studs FIGURE 3 Remove the complete planetarv cover 2 18 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY FIGURE 10 Take out the pins and remove the steering case stic hammer 3 For pin removal details see PLANETARY REDUCTION GEAR NOTE p 17 Hammer alternately on several equidistant points l D Li W 442 d 1 FIGURE 12 Using a puller remove the planetary gears 10 Li FIGURE 9 Draw out the wheel hub 7 NOTE Write down direction of installation of planetary gears ASM 0029E 223 Axle Service Manual Dana Holding Corporation 19 DISASSEMBLY FIGURE 17 Remove the outer thrust blocks of bearings 8 16 by driving a pin driver in the slots provided on the hub 7 NOTE Hammer alternately to avoid thrust block clamping and deformation FIGURE 15 Remove seal ring 15 from wheel hub 7 NOTE Mark the seal ring position FIGURE 18 Using a puller remove seal ring 17 from stee ring case 3 NOTE Write down seal ring orientation 20 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY FIGURE 19 Using driver T1 See drawing T1 p 26 extract the guide bushing 18 of twin u joint Only if necessary remove any damaged studs 19 which need to be replaced
50. 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 lengthwavs 4 Do not admit any other person inside the work area mark off the area hang warning signs and remove the igni tion key from the machine 5 Use only clean quality tools discard all worn damaged lowquality or improvised wrenches and tools Ensure that all torque wrenches have been checked and calibrated 6 During maintenance operations always wear protective glasses safety footwear protective gloves and all P P E Personal Protective Equipment in function of the risks which the workers may be exposed to 7 Should you stain a surface with oil remove marks straight away 8 Dispose of all lubricants seals rags and solvents once work has been completed Treat them as special waste and dispose of them according to the relative law provisions obtaining in the country where the axles are being overhauled 9 Make sure that only weak solvents are used for cleaning purposes avoid using turpentine dilutants and toluol xylolbased or similar solvents use light solvents such as Kerosene mineral spirits or water based environment friendly solvents 10 For the sake of clarity the parts that do not normally need to be removed have not been r
51. this quantity deduce the type of material 8 discs friction material PAPER 10 discs friction material MOLV ASM 0029E 223 Axle Service Manual Dana Holding Corporation 97 ASSEMBLY ASSEMBLY MOLY FRICTION DISCS V 9 FIGURE 8 Check the disc pack thickness V applying 3000 N 5 V measurement must be 17 4 0 08 mm PAPER FRICTION DISCS V FIGURE 9 Check the disc pack thickness V applying 3000 N 5 V measurement must be 17 35 17 50 mm Dip the complete disc pack in oil with LS additive at least one hour before to assembly for details about oil see OIL DRAINING MANDATORY PROCEDURE p 12 NOTE Check the total dimension of the disc pack before instal ling if this measurement does not respect the predifined value install a new disc pack New disc pack doesn t need measurement because supplied as subassembly they already respect the predi fined value It is mandatory to install discs of the same material ofthe original installation 98 Dana Holding Corporation Dip the complete disc pack in oil with LS additive at least 24 hours before to assembly for details about oil see OIL DRAINING MANDATORY PROCEDURE p 12 NOTE Check the total dimension of the disc pack before instal ling if this measurement does not respect the predifined value install a new disc pack New disc pack doesn t need measurement because supplied as subassem
52. ve the counterwasher 1 FIGURE 5 Remove braking discs 2 3 noting down direc tion of assembly NOTE If disks are not to be replaced avoid changing their posi tion 106 Dana Holding Corporation ASM 0029E 223 Axle Service Manual DISASSEMBLY It RDN Ca ent Sr CRT one SC wa E EE see path Z lt SE SE ANS R LAA 2 a SU FIGURE 7 Remove braking discs 2 3 noting down direc tion of assembly NOTE If disks are not being replaced avoid changing their posi tion FIGURE 8 Remove the reversal springs 7 ASM 0029E 223 Axle Service Manual Dana Holding Corporation 107 DISASSEMBLY FIGURE 10 Slowly introduce low pressure compressed air through the connection member for the service brake P1 in order to extract the piston 9 Hold the piston 9 back as it may be suddenly ejected and damaged 108 Dana Holding Corporation ASM 0029E 223 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 14 Fit the reversal springs screws 7 on the piston 9 Tighten with torque wrench setting of 10 15 N m FIGURE 11 Insert the stroke automatic regulation springs 6 place them in line with the piston 9 Use only new screws pre treated with Driloc locking adhe sive Threads must be cleaned from oil Degrease only non pre treated threads 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
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