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1. FIGURE 5 Remove the upper king pin 2 complete with front seal ring 4 and shims 3 FIGURE 3 Disconnect the tapered pins of the articulation from the steering knuckle using a puller FIGURE 6 Loosen and remove the capscrews 6 and remo ve the bottom king pin 7 NOTE Screws cannot be re used 30 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 7 Remove the bearing 5 from the king pin 2 7 Remove the sealing ring 4 from the king pin 2 7 i n FIGURE 11 Using a puller remove the sealing ring 12 from FIGURE 8 Remove the complete steering knuckle the steering knuckle FIGURE 9 Remove snap ring 8 and the shim 9 from the FIGURE 12 Remove the snap ring 11 from the steering steering knuckle knuckle ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 31 DISASSEMBLY FIGURE 13 Using a puller remove the bearing 10 from the steering knuckle FIGURE 14 Using an extractor for inner parts remove the top and bottom thrust blocks 5 FIGURE 15 Using an extractor for inner parts remove the seal ring 14 and subseguently the bushing 15 NOTE Write down the direction of assembly of seal ring Write down the assembly side of the connection notch 32 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 16 Lub
2. 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 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
3. lt gt SPICER Off Highway Products Service Manual Axle 725 539 725 540 ASM 0151E October 2012 CONTENTS INTRODUCTION u L u u an irse 5 SPECIFICATIONS 6 DEFINITION OF VIEWPOINTS tette tette tette tt tette 6 cuc ce ate i nicum a M M ANN 6 CONVERSION TABLES ee UU PM 7 TORQUE see OR 8 MN A 8 METT 8 WHEEL NUT TIGHTENING TORQUES rete tnnc 9 MEN 10 MAINTENANCE POINTS tegulis ute luas cn 10 MAINTENANCE INTERVALS ness conscious AD DM C LED LA aaa 11 ADJUSTMENT DE en 11 LUBRICANT amp SEALANT SPECIFICATIONS o oooocoooooocooocooccocoooooo Woooooooooooom m 12 SKEE CA TON eo 13 SWINGING SUPPORT ana 15 EXPLODED VIEW a 15 aa nana 16 e EN 18 PLANETARY REDUCTION GEAR kaan koi 21 EXPBODEDWIE ERU ELM I I Me LI 21 22 uA LC uL mM du LE M UM IM E 25 STEERING KNUCKLE i nuk w usa 29 W nun UL E 29 EV ADM M M DREAM NM EM ETE 30 NN MM a AE 33 STEERING CYLINDER se 39 VIEW RN RO T TE 39 EAN 40 RR HIN NORD ni 42 BEVEL PINIONI rrun unn 47 ExXBLODED VIE A
4. 5 and the thrust block 5 Lubricate with OPTIMOIL grease the contact surfaces of the king pin and steering knuckle ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 28 Install the king pin 7 with new capscrews 6 of FIGURE 31 Tighten the new capscrews 1 of top king pin 2 bottom articulation pins in sequence using the criss cross in sequence using the criss cross method method Torque wrench setting 104 128 N m FIGURE 32 Position a gauge preset it to 1 mm and reset it to Zero N FIGURE 33 Check vertical gap using a lever FIGURE 30 Prepare a series of shims 3 of 2 5 mm to be as sembled above the upper king pin 2 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 35 ASSEMBLY FIGURE 34 Loosen and remove the capscrews 1 from the king pin 2 E FIGURE 35 Calculate the difference between sizes First step shim Measured Backlash and Preload Draw so as to obtain the size S ofthe shim 3 that will go under the king pin King pin Preload Draw z 0 5 0 6 mm S First step shim Measured Backlash Preload Draw Example First step Shim 2 5 mm Measured Backlash 1 mm S 2 5 mm 1 mm 0 5 mm 1 mm S 1 0 mm 36 Dana Holding Corporation FIGURE 36 Lubricate the surface of the sealing ring 4 and assemble it into position Carefully check that the rings 4 are properly oriented Ins
5. ASM 0151 725 539 8 725 540 Axle Service Manual Dana Holding Corporation 69 ASSEMBLY ASSEMBLY FIGURE 13 Insert the two half bolts 11 spherical washers 10 and satellite wheels 9 FIGURE 10 As to ring 16 the side without notches must face outwards FIGURE 14 Partially insert the long bolt 13 satellite wheels 9 and spherical washers 10 FIGURE 11 FRICTION UNIT COMPOSITION Friction discs with increased shim 16 steel discs 5 and fric tion discs 15 alternated end disc 17 4 N l g 1 r _ d FIGURE 15 Place the planetary 9 and the spherical washer 10 in the box and fix with a fake pin of suitable diameter FIGURE 12 Place a friction unit 2 and planetary gear 8 into the half box 4 70 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 17 Satellite wheels 9 spherical washers 10 and FIGURE 20 Place a friction unit and planetary gear 8 into completely insert the long bolt 13 the half box 4 FIGURE 18 Bring the pin holes in line with the help of a pin FIGURE 21 Mount the locking half box 7 onto the half box driver 4 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 71 ASSEMBLY FIGURE 22 Mount the gear ring 3 and fasten it to the diffe FIGURE 24 Using a driver with an adequate diameter install rential box
6. If working in heavy conditions half intervals should be used Initially after 100 working hours OPERATION MEMBER CONDITIONS FREQUENCY LUBRICANTS Greasing Articulations MOLIKOTE ADJUSTMENT AND CHECKS OPERATION FREQUENCY SERVICE BRAKE CIRCUIT Wires nuts Tightening Every 200 hours Only for mineral oil use e g ATF Dexron II Make sure that master cylinder seals are suitable for mineral oil Initially after 10 working hours ASM 0151 725 539 amp 725 540 Axle 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
7. 2 Remove the shim washer 6 and the v ring 5 FIGURE 6 Remove the swinging support 7 on the side op posite the drive FIGURE 3 Use a screwdriver to remove the o ring 3 16 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 7 Remove the shim washer 11 and the v ring 10 FIGURE 9 Using an extractor remove the bushing 9 from the swinging support 7 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 17 ASSEMBLY ASSEMBLY FIGURE 13 Install the grease zerk 2 and tighten to a torque wrench setting of 5 8 N m FIGURE 10 Using tool T1 See drawing T1 p 73 mount the bushing 4 in the swinging support 1 on the pinion side FIGURE 14 Install the v ring 5 and the shim washer 6 FIGURE 11 The o ring 3 housing should be mounted exter nally NOTE Lubricate with grease before installing NOTE The hole for the grease zerk on the bushing 4 is oriented to wards grease zerk hole A FIGURE 15 Install the swinging support 1 NOTE Check that it is properlv oriented Using a grease gun lubricate the swinging support hou sing FIGURE 12 Lubricate the o ring 3 to hold in position and in stall it in the bushing 18 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 16 Make sure hole for the grease zerk on the bu shing 9 sho
8. Always wear gloves and non slip rubber shoes when performing repair work 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 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 13 14 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual SWINGING SUPPORT EXPLODED VIEW ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 15 DISASSEMBLY DISASSEMBLY FIGURE 1 Remove the swinging support 1 on the drive si de FIGURE 5 Using an extractor remove the bushing 4 from the swinging support 1 FIGURE
9. Remove the internal bearing 18 24 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 21 Install the external bearing 15 FIGURE 18 Position the tool T2 See drawing T2 p 73 and NOTE press the thrust blocks 15 18 into the hub 17 all the way Using a plastic hammer drive the bearing to the limit stop down by lightly hammering around the edge FIGURE 23 Insert the snap ring 14 in order to fix the flange FIGURE 20 Position the sealing ring 19 in the special tool 12 in the crown 13 T3 See drawing T3 p 73 and press into its seat NOTE Check that the ring 19 is correctly oriented Flat surface should be visible after mounting NWARNING Personal injury can result when installing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses during this procedure ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 25 ASSEMBLY FIGURE 24 Match up the punch marks on the joint case and FIGURE 27 Insert a new o ring 16 on the centering diameter the crown wheel carrier flange of wheel hub NOTE In order to hold the o ring 16 in position apply grease to it FIGURE 25 Install the complete crown flange 12 using a plastic hammer and alternately hammering on several equidi stant points FIGURE 28 Install the planetary gear 5 into
10. Service Manual HYDROLOCK DIFFERENTIAL UNIT EXPLODED VIEW ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 57 DISASSEMBLY DISASSEMBLY If disassembly is carried out in order to replace crown wheel and pinion bearings or planetary gear break up distance washers and calculate clearances as indicated in the sec tions regarding removal disassembly assembly and instal lation of differential unit and bevel pinion FIGURE 1 Connect a suitable lifting system Loosen and re move the screws 27 securing the arm to the body Remove the arm FIGURE 4 Remove the snap ring 15 Personal injury can result when removing snap ring The appropriate safety eguipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure FIGURE 5 Remove the hydraulic block discs 13 14 one af ter the other FIGURE 3 Extract the bearings 25 29 from the differential carrier 58 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 6 Remove the capscrews 1 of the crown 2 FIGURE 9 Remove the three spider blocking pins 9 by Note the position of assembly using a pin driver FIGURE 7 Remove the crown 2 FIGURE 10 Move the two opposite mounted short bolts 7 to the outside of the box using the same pin driver FIGURE 8 Remove the shim washer 3 and the planetary gear 4 FI
11. of the cylinder head ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY Personal injury can result when removing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure FIGURE 9 Continue hammering until the head is ejected from the cylinder FIGURE 7 Hammer the piston on the rear of the head using a plastic hammer until the head is ejected from the cylinder mA 2 FIGURE 10 Remove all seals anti extrusion rings and scra per rings from head cylinder and piston NOTE All seals must be replaced every time the unit is disas sembled Particular attention must be paid not to damage the seats of both seals and piston slide FIGURE 8 Remove the snap ring of the cylinder head Personal injury can result when removing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 41 ASSEMBLY ASSEMBLY nil quad ring seal ring guide ring FIGURE 14 Prepare the piston by fitting it with the o ring and the seal scraper ring FIGURE 11 After applying grease install the sealing ring of the shaft the scraper ring and the guide ring in the head In order to facilitate assembly apply grease quad ring FIGURE 12 Fit the sea
12. 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 lubricated 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 ASM 0151 725 539 amp 725 540 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
13. the planetary gear cover 4 using a drift Drylock 68 5 Nm FIGURE 26 Tighten the screws 11 in two stages using the criss cross method Final torque wrench setting 68 75 N m 26 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY 80 95 FIGURE 29 Lock into position the planetary gears 5 with the FIGURE 32 Install the oil level plug 1 snap rings 7 Torque wrench setting for screws 80 95 N m Personal injury can result when installing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses during this procedure FIGURE 30 Fit the planetary carrier cover 4 onto the hub 17 FIGURE 31 Lock the planetary carrier cover 4 by tightening the screws 3 Torque wrench setting for screws 25 30 N m ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 27 28 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual STEERING KNUCKLE EXPLODED VIEW ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 29 DISASSEMBLY DISASSEMBLY FIGURE 4 Loosen and remove the capscrews 1 from the 4 king pin 2 FIGURE 1 Remove the complete crown flange For details see PLANETARY REDUCTION GEAR p 21 NOTE Screws cannot be re used fo WA 1 E T 7 4 4 1
14. 1 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 63 ASSEMBLY FIGURE Position satellite wheels 6 spherical washers FIGURE 36 Position the crown 2 on the differential carrier 5 and completely insert the long bolt 8 and lock it with screws 1 Loctite 243 115 142 Nm FIGURE 34 Bring the pin holes in line using pin driver FIGURE 37 Install only new screws 1 pre treated with lo Insert pins 9 to end of stroke cking adhesive using the criss cross method Torque wrench setting 115 142 N m FIGURE 35 Insert planetary gear 4 together with washer 3 il FIGURE 38 Insert and substitute if necessary the discs 13 14 of the differential lock NCAUTION First and last disc must be of steel material 64 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 39 Install the snap ring 15 Personal injury can result when installing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure NOTE Make sure the ring is properly set in its seat FIGURE 42 Insert a new o ring on the centering diameter of the arm Position the arm on the central body Tighten nuts 27 in two stages using the criss cross method FIGURE 40 Heat the bearings 25 29 to approximately 212 F 100 C and fit into th
15. A u u a E Quam qa LEE E E EE E 47 SEM Dou azas 48 SEM E M LM UE 51 HYDROLOCK DIFFERENTIAE UNIT seas 57 EXPLODED VIEW M NER 57 Te 58 NN 62 LIMITED SLIP DIFFERENTIAL UNIT oo 67 EN 67 ER NE ER 68 MN 70 SPEGIAL TOOLS sa 73 NC T 73 TN 73 REE NE 73 Vs 74 pA I M LP M 75 TN 76 Frasen 77 JE na Aa na 78 p 79 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 3 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle 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 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 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
16. GURE 11 Remove the bolts using a drift 8 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 59 DISASSEMBLY FIGURE 12 Remove the cross bolts 30 FIGURE 15 Connect a suitable lifting system to the second arm Loosen and remove the screws 22 securing the arm to the body Remove the arm FIGURE 13 Remove the two half bolts 7 spherical washers 5 and satellite gears 6 FIGURE 16 Using a puller remove the thrust block of the be aring 25 Remove the shims 24 located under the outer thrust block of the bearing 25 FIGURE 14 Remove the shim washer 11 and the planetary gear 10 FIGURE 17 Remove the snap ring 17 AWARNING Personal injury can result when removing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure 60 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 21 Remove rings 20 21 from cylinder NOTE All seals must be replaced every time the unit is disas sembled Particular attention must be paid not to damage the seats of both seals and piston slide FIGURE 20 Position the complete piston under a press and disassemble flange 16 bearing 18 and piston 19 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 61 ASSEMBLY ASSEMBLY DA i
17. P gt FIGURE 25 Lubricate the piston seating and install the pi LL mi P ston pack FIGURE 22 After applying grease install the o ring 20 21 Tap lightly with a mallet to seat the piston 19 completely inside the cylinder Note the position of assembly FIGURE 26 Install the snap ring 17 press all the way down Personal injury can result when installing snap ring The appropriate safety equipment must be worn To avoid injury to your eyes wear protective glasses du ring this procedure NOTE Make sure the ring is properly set in its seat FIGURE 24 Position the flange 16 in the bearing 18 and press all the way down 62 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 27 Insert the thrust block 25 and the shims 24 FIGURE 30 Insert the two half bolts 7 spherical washers 5 and satellite gears 6 NOTE For the regulation of the pre charge bearings use the ori ginal shims pack distance Loctite 243 200 210 N m I FIGURE 31 Partially insert the long bolt 8 satellite gears 6 and spherical washers 5 FIGURE 28 Insert a new o ring on the centering diameter of the arm Position the arm on the central body Tighten nuts 22 in two stages using the criss cross method FIGURE 32 Insert the crossbolt 30 in the correct position FIGURE 29 Insert planetary gear 10 together with washer 11 ASM 015
18. RE 21 Install the predefined quote shim 6 0 3 mm in its seat as shown in figure Do not install the shim 6 if the gap between steering cylin der and armi is less than the shim 0 3 mm Dana Holding Corporation 43 ASSEMBLY 200 210 N m FIGURE 22 Apply Loctite 243 to the threads and tighten the FIGURE 25 Center the piston by slowly moving it first in one cylinder 5 screws 4 using the criss cross method direction then in the other and position it half way on the stro Torque wrench setting 200 210 N m ke FIGURE 23 Apply Loctite 270 to the threads and connect the FIGURE 26 Apply tools T6 See drawing T6 p 76 to the hubs steering bars 3 by tightening the terminals onto the piston and lock them Using a level check that tools are perfectly stem flat Torque wrench setting 240 270 N m 200 220 N m A FIGURE 27 Without moving the piston check front and rear FIGURE 24 Insert the pins 2 in the steering case and lock distance at the edge of tools into position using a torque wrench setting of 200 220 N m Maximum difference 2 2 mm NCAUTION In order to check the rear distance rotate the bevel pinion Check that rubber guards are intact and check that tools 0 44 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 28 CONVERGENCY ADJUSTMENT Loosen the nuts and tighten them onto the ball and socket joints Hold the arti
19. Service Manual ASSEMBLY If torque exceeds the maximum value then the size of shim 51 3 needs to be increased If torque does not reach the minimum value then the size of shim S1 3 needs to be reduced FIGURE 29 In order to hold the shim 3 in position apply grease to it Assemble shims 3 washer 2 and nut 1 FIGURE 32 Loosen and remove the nut 1 washer 2 and shims 3 Remove the flange 4 2 0 310 N m FIGURE 30 Apply the T7 See drawing T7 p 77 tool onto the flange 4 Lock the wrench and tighten the nut using a torque wrench up to a minimum required torque setting of 270 310 N m FIGURE 33 Lubricate and fit the sealing ring 5 onto tool T9 See drawing T9 p 79 Install the ring into the seat FIGURE 31 Apply onto the pinion 10 the bar hold and using a torque meter check the torque of the pinion Torque 0 6 1 6 Nm FIGURE 34 Replace the outer o ring 6 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 53 ASSEMBLY FIGURE 38 Fit the bearing disc 11 complete with shims 12 in the intermediate cover Loctite 243 200 210 N m FIGURE 36 In order to hold the shim 3 in position apply grease to it FIGURE 39 Insert a new o ring on the centering diameter of Assemble shims 3 washer 2 and nut 1 the arm Position the arm on the central body Tighten nuts 14 in two stages using the criss cross me
20. al T7 ASM 0151 725 539 amp 725 540 Axle Service Manual SPEGIAL TOOLS 230 X detail X detail 195 VA e UD Dana Holding Corporation 77 24 O O I lt e LL al Op M p SAW S 259 SPEGIAL TOOLS 053 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual
21. culations still and rotate the ball and so Cket joints Once the convergency has been adjusted lock the nuts Torque wrench setting for nuts 240 2 0 N m NOTE Adjust by the same amount on each steering rod FIGURE 29 ADJUSTING THE STEERING ANGLE Insert the end stroke screws and adjust to 59 mm ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 45 46 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual BEVEL PINION EXPLODED VIEW ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 47 DISASSEMBLY DISASSEMBLY FIGURE 4 Extract the complete differential unit FIGURE 1 Connect a suitable lifting system Loosen and re move the screws 18 securing the arm to the body Remove the arm FIGURE 5 Connect a suitable lifting system to the second arm Loosen and remove the screws 14 securing the arm to the body Remove the arm FIGURE 2 Use a screwdriver to remove the o ring FIGURE 6 Use a screwdriver to remove the o ring FIGURE 3 Using a puller remove the thrust block of the be aring 15 from the arm Remove the shims 16 located under the outer thrust block of the bearing 15 48 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 7 Using a puller remove the thrust block of the be aring 11 from the arm Remove the shims 12 located
22. e differential box 12 NOTE Once the bearing has cooled down lightly lubricate bea ring 25 29 with SAE85W90 oil ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 65 66 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual LIMITED SLIP DIFFERENTIAL UNIT EXPLODED VIEW ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 67 DISASSEMBLY DISASSEMBLY NN FIGURE 4 Remove the planetary gear 8 and the whole fric tion assembly concerned FIGURE 1 If the bearing need replacing extract the bearings 2 from the differential carrier 4 E FIGURE 5 Remove the three spider blocking pins 12 by using a pin driver Move the two opposite mounted short FIGURE 2 Remove the capscrews 6 from the crown 3 bolts 11 to the outside of the box using the same pin driver Use a plastic mallet to detach the ring gear 3 from the diffe rential assembly FIGURE 6 Remove the two half bolts 11 spherical washers 10 and satellite wheels 9 FIGURE 3 Using a plastic hammer take the half box 4 7 to pieces 68 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY p ME FIGURE 7 Remove the bolts 13 with the help of a drift and spherical washers 10 and satellite wheels 9 FIGURE 9 Remove the planetarv gear 8 and the whole fric tion assembiv 2 concerned
23. ed formula to ob FIGURE 21 Partially insert the thrust block of the bearings 7 tain the necessary value to the successive calculation 9 C A B Example C 1 1 0 1 2 1 mm NOTE The smaller shims 8 must be placed in between the thi cker ones o y Th FIGURE 22 Install tension rod and guidetool 18 See drawing T8 p 78 on the thrust block of the external 7 and inner 9 bearing ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 51 ASSEMBLY FIGURE 23 Connect the tension rod to the press and move FIGURE 26 Heat the outer bearing 7 to a temperature of the thrust block of the bearing 7 9 into its seat about 176 F 80 C and fit it onto the pinion 10 Disconnect the press and remove the tension rod NOTE NOTE Lightly lubricate bearing 7 with SAE85W90 oil Before starting the next stage make sure the thrust block has been completely inserted into its seat FIGURE 27 Install the flange 4 onto the pinion 10 without the sealing ring 5 FIGURE 24 Heat the inner bearing 9 to about 212 100 and fit it to the pinion 10 NOTE Once the bearing has cooled down lightly lubricate bea ring 11 with SAE85W90 oil FIGURE 28 Install the first step pinion shims S1 3 Example S1 1 6 mm FIGURE 25 Fit the pinion 10 in the central body 52 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle
24. er oinm oor roum 2 _ 908 1085 156 Hm 1140 160 1009 1807 Nn eokimm 1511 670m 2108 2360 Nm 2302 2577 Nm 25052855 Nm 2700 3002 Nm 8 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle 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 M18 x 1 5 mm 330 N m 460 N m WHEEL NUTS WITH S INTEGRATE Ist M20 x 1 5 mm 490 N m 630 N m SPHERICAL COLLAR gt p i TM T FLAT COLLAR WHEEL M18 x 1 5 mm 270 N m 360 N m NUTS WITH SEPARATE aa zl M20 x 1 5 mm 360 N m 450 N m WASHER M22 x 1 5 mm 460 N m 550 M18 x 1 5 260 N m 360 N m WHEEL NUTS WITH IN II TEGRATE SEAT M20 x 1 5 mm 350 N m 500 CAPTIVE WASHER i 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 charact
25. eristics 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 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 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 9 MAINTENANCE MAINTENANCE MAINTENANCE POINTS 1 Oil filling plug 2 Oil draining plug 3 Check level plug 4 Grease zerk 10 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual MAINTENANCE MAINTENANCE INTERVALS OPERATION FREQUENCY LUBRICANTS Differential Monthly Check levels Planetary reduction Every 200 hours SAE85W90 API GL4 MIL L 2105 Differential Every 1000 1200 hrs With additives for oil bath brakes Oil change Planetary reduction Every 1000 1200 hrs It is recommended to set the axle s oil changes according to the machine maintenance intervals
26. fication 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 SPICER ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 5 SPECIFICATIONS DEFINITION OF VIEWPOINTS Qf Q Q FET fee 49 LEFT SIDE mw RIGHT SIDE LATO SINISTRO LATO DESTRO LINKE SEITE RECHTE SEITE LADO IZQUIERDO LADO DERECHO COTE GAUCHE COTE DROITE DATA PLATE SPIGER MFG BY DANA ITALIA S p A MADE IN COMO ITALY 1 Type and model unit modification index 2 Differential type 3 Reduction ratio 4 Serial number 5 Axle number 6 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual CONVERSION TABLES CONVERSION TABLES UNITS OF PRESSURE 1 ATM 1 BAR 10 PA 14 4 PSI UNIT OF WEIGHT ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 7 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT TYPE OF BOLT rors Jiosriomezoji ss ioswm wz
27. 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 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 CLASSIFICATION This manual classifies units according to part numbers For a correct interpretation classification is indicated as follows bb O upto the part number O gt P from the part number When no classi
28. l and local regulations AWARNING Hot oil and components can cause personal injury Avoid skin contact FIGURE 4 FIGURE 5 Use a screwdriver to remove the o ring 16 FIGURE 2 Remove the locking screws 3 of planetary cover 4 22 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual DISASSEMBLY FIGURE 9 Tighten two M8 screws in the special threads Tighten by one turn alternately 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 10 Remove the crown 13 FIGURE 7 Remove the planetary gears 5 and the bearings 6 FIGURE 11 Remove the snap ring 14 from the crown 13 WARNING Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to FIGURE 8 Loosen and remove the screws 11 from the eyes wear eye protection equipment crown flange 12 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 23 DISASSEMBLY FIGURE 13 Harness the wheel hub 17 and partially extract FIGURE 16 Remove the thrust blocks 15 18 from the bea using an extractor rings and force a puller into the appropriate slots on the hub NOTE Avoid clamping or deformation of the thrust blocks FIGURE 14 Remove the external bearing 15 and the hub 17 FIGURE 17
29. l and the backup ring onto the outside of the head FIGURE 15 Apply grease to head seals fit the head onto the piston and push it into the cylinder using a plastic hammer Introduce the stop ring and ensure that it sets in the seat of cylinder In order to facilitate assembly apply grease to the outer sur face of the piston Do not roll the seal up Thoroughly check that positioning of the backup ring is cor rect NOTE Insert the head to line it up with the edge of the cylinder X seal ring scraper ring FIGURE 13 After applying grease install the sealing ring of the shaft and the scraper ring in the head 42 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY FIGURE 16 Push the piston into the cylinder using a plastic hammer NOTE Apply a little grease to seals and cylinder as FIGURE 17 Lightly tap the cylinder head with a plastic ham mer to push it inside the cylinder NOTE Insert the head to line it up with the edge of the cylinder FIGURE 18 Introduce the stop ring and ensure that it sets in the seat of cylinder ASM 0151 725 539 amp 725 540 Axle Service Manual FIGURE 19 Fit the steering cylinder 5 into its seat Loctite 243 200 210 Nim AT g QALU FIGURE 20 Apply Loctite 243 to the threads and tighten the cylinder 5 screws 4 using the criss cross method Torque wrench setting 200 210 N m FIGU
30. ricate the bushing 15 and the seat and in stall the bushing 15 using tool T4 See drawing p 74 FIGURE 20 Install the bearing 10 snap ring 11 and careful ly check it is completely inserted FIGURE 17 Lubricate and fit the sealing ring 14 onto tool T5 See drawing T5 p 75 install the rings into the arm Pay particular attention to the direction of assembly of the rings FIGURE 21 Lubricate the outer surface of the sealing ring 12 and assemble it into its position FIGURE 18 Lubricate the top and bottom thrust blocks 5 and fit them into the fulcrum holes of the arm NOTE Verify at end of stroke ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 33 FIGURE 22 Lubricate the terminal of the u joint 13 and in stall in the steering knuckle FIGURE 23 Install the shim 9 and snap ring 8 of the stee ring knuckle ays Il FIGURE 24 Tighten fully into the hole provided two double joint lifting eyes size M16 connect to suitable lifting gear and tighten Pay attention not to damage the dust cover rings and the se aling rings Install the steering knuckle 34 Dana Holding Corporation FIGURE 25 Using a drift insert the front seal thrust plate 4 Lubricate the surface of the sealing ring 4 and assemble it into position Carefully check that the rings 4 are properly oriented FIGURE 27 Grease generously the bearing
31. tall the bearing 5 FIGURE 37 Grease generously the bearing 5 and the thrust block 5 A 104 128 N m FIGURE 38 Tighten the new capscrews 1 of articulation pins 2 in sequence using the criss cross method Torque wrench setting 104 128 N m ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY 200 220 N m FIGURE 39 Insert the king pins in the steering knuckle and lock into position using a torque wrench setting of 200 220 N m Check that rubber guards are intact FIGURE 40 Fit the planetary gear cover onto the wheel hub For details see PLANETARY REDUCTION GEAR p 21 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 37 38 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual STEERING CYLINDER EXPLODED VIEW Z ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 39 DISASSEMBLY DISASSEMBLY FIGURE 2 Disconnect the tapered pins of the articulation 2 from the steering knuckle using a puller FIGURE 3 Disconnect steering bars 3 from the piston 40 Dana Holding Corporation FIGURE 4 Remove the securing screws 4 from the steering cylinder FIGURE 5 Extract the cylinder 5 using a plastic hammer NCAUTION Before attempting to disassemble the unit drain the oil in the cylinder chambers completely y FIGURE 6 Remove the snap ring
32. teswm 2 Mex 25mm 200 202mm _ 256 24Nm monn farzeanm MOK Sm em frem 129 100 on morran mecnm _ Detox gm 20 rnm oo Sani 2 209 901 Nm 900 401 Nm aoste Nm s00 seem _ 990 401 Nm 0 7 2 7 _ jss senm srs esum ra Tora _ __ rsen 000 THD SOx mm ara 1626 em 10142115 Nm 2088 2305 Wim 2200 2520 Nm 2494 257 Nm FINE PITCH SIZE OF BOLT TYPE OF BOLT NO eenemeze o 120 tocwez70 Maxim 7 fe sanm menn feswann _ 25mm 2 ris rssnm recen mer cct rosen _ izxismm roenn KE aean 261 2690 jew xenm ns zsrm aoe asenn 99 KE AN Te 0 era ranm _ 708 814N CAR atm s
33. thod 2 0 310 N m FIGURE 37 Apply the T7 See drawing T7 p 77 tool onto the flange 4 Lock the wrench and tighten the nut using a torque wrench FIGURE 40 Install the complete differential unit up to a minimum required torque setting of 270 310 N m 54 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY i ja FIGURE 41 Insert thrust block of the bearing shims 16 of an initial thickness of about 1 30 mm FIGURE 42 Fit the bearing disc 15 complete with shims 16 in the intermediate cover FIGURE 43 Insert a new o ring on the centering diameter of the arm Position the arm on the central body Tighten nuts 18 in two stages using the criss cross method ASM 0151 725 539 amp 725 540 Axle Service Manual FIGURE 44 Apply onto the pinion a torque metre and check that torque will increase by 1 1 5 N m as aresult of differen tial bearing preload Example pinion torque 0 6 1 6 N m Pinion differential torque 1 6 3 2 N m NCAUTION If bearings are not new check the static torque if bearings are new check the continuous torque FIGURE 45 Install a dial indicator as shown and shift the flan ge to check the tolerance between the bevel gear teeth Check the backlash at the input flange bolt hole B C D 42 mm Tolerance 0 25 0 35 mm Dana Holding Corporation 55 56 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle
34. uld be oriented towards grease zerk hole FIGURE 17 Using tool T1 See drawing T1 p 73 mount the bushing 9 in the swinging support 7 on the pinion s oppo site side FIGURE 18 Install the v ring 10 and the shim washer 11 NOTE Lubricate with grease before installing ASM 0151 725 539 amp 725 540 Axle Service Manual FIGURE 19 Install the grase zerk 8 and tighten to a torque wrench setting of 5 8 N m FIGURE 20 Install the swinging support 7 NOTE Check that it is properly oriented Using a grease gun lubricate the swinging support hou sing Dana Holding Corporation 19 20 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual PLANETARY REDUCTION GEAR EXPLODED VIEW Q gt Vi IR 5 YS HD 77 S lt oS S 5 UJ ECU 7 S 2 222 Q gt XU ASM 0151 725 539 8 725 540 Axle Service Manual Dana Holding Corporation 21 DISASSEMBLY DISASSEMBLY NCAUTION Perform all operations on both arms FIGURE 3 Disjoin the spider cover 4 from the hub by alter natively forcing a screwdriver into the appropriate slots Make sure all fluids are contained during inspection main tenance tests adjustment and repair of the product Prepa re a suitable container to collect the fluid before removing any component containing fluids Dispose of all fluids fol lowing lega
35. under the outer thrust block of the bearing 11 FIGURE 8 Use the T7 See drawing T7 p 77 special wrench on the flange 4 and loosen the nut 1 NOTE If disassembly is difficult heat the nut 3 at approximate ly 176 F 80 C FIGURE 12 Using an internal extractor remove the seal ring 5 NCAUTION Take care not to damage the seal ring seating FIGURE 9 Loosen and remove the nut 1 washer 2 and shims 3 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 49 DISASSEMBLY m FIGURE 16 Using an internal extractor remove the thrust blocks 7 9 FIGURE 14 Using a puller and a press remove the inner be aring 9 from the pinion 10 FIGURE 17 Using an internal extractor remove the thrust block of the internal bearing 9 as well as the shim washers 8 FIGURE 15 Extract the bearing 7 50 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual ASSEMBLY ASSEMBLY FIGURE 20 Check nominal dimension as marked on the k 4 new pinion FIGURE 18 Check the thickness of first step pinion shims 8 Execute the calculation following the indicated formula to ob Example A 1 1 mm tain the value of necessary shims S C D Example S 1 0 1 0 9 mm FIGURE 19 Check nominal dimension B as marked on the old pinion Execute the calculation following the indicat
36. with screws 6 the fi rst bearing 2 Turn the unit upside down and install the second bearing 2 Use only new screws Loctite 243 104 128 Nm FIGURE 23 Lock the half box with screws 6 coated with Loctite 243 Lock the gear ring 3 by tightening the screws 6 to a torque of 104 128 N m Use the alternate and criss cross tightening method 72 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual SPECIAL TOOLS T1 ASM 0151 725 539 amp 725 540 Axle Service Manual Dana Holding Corporation 13 SPEGIAL TOOLS T4 262 247 40 82 20 2x45 14 68 30 8H8 0 022 0 1 i 8 p si 5 S e 65 0 04 0 08 10 74 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manual SPEGIAL TOOLS T5 a ASSSSSSSSSSSSSSSSSSSSSSSSSS KAN IWu EI RR lt es NNNNNNNNNNNNNNNNNNNNNNNNNNNN EG DID er U PROTECT FROM CARBURIZING ASM 0151 725 539 8 725 540 Axle Service Manual Dana Holding Corporation 75 SPEGIAL TOOLS T6 76 Dana Holding Corporation ASM 0151 725 539 amp 725 540 Axle Service Manu

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