Total view of the steering axle.
Disassemble - Final Drive
Loosen and remove oil drain plug. Drain the oil in a suitable container.
Loosen hex. head screws. Separate planetary carrier assembly from the hub, using back-off screws, and remove it.
(S) back-off screws
Remove the snap rings. Press planetary shafts out of the planetary carrier. Remove released planetary gears, washers and roller bearings.
Squeeze circlip out, pull sun gear from the universal shaft and remove thrust washer.
Unlock slotted nut.
Loosen first slotted nut, remove lock plate and remove the second slotted nut.
(S) pin spanner
Fasten a hoist and lifting device to the hub and pull off the internal gear.
(S) lifting yoke
Pull off hub assembly, paying attention to the released tapered roller bearing.
Lift shaft seal out of the hub, remove washer and tapered roller bearing.
(S) pry bar
Loosen both allen-head screws and separate brake drum from the hub.
Loosen hex. head screws from the anchor pin fastening.
Remove anchor pin by means of puller.
(S) puller
Remove both brake shoes.
Remove brake line connection, loosen both hex. head screws and remove complete wheel brake cylinder.
Loosen allen-head screws and remove the brake anchor plate.
Mark hub carrier with steering knuckle hull and tap it loose from the steering knuckle hull.
Remove sealing components.
(S) pry bar
Pull sleeve out of the hub carrier.
(S) support
(S) internal puller
Pull universal shaft out of the axle housing.
 |
The shaft can possibly loosen suddenly. Possible personal injury can be the result. Be sure no one is near the direction of the removal or the components being released. |
 |
Unlock and loosen castle nut. Press shaft out, using a three leg puller. Separate tie rod from steering knuckle hull (housing). Pay attention to the released components.
Mark king pin cap with steering knuckle hull. Loosen hex. head screws and remove king pin caps on top and bottom. Remove released components from the steering knuckle bearing.
Remove steering knuckle hull. If required, drive bearing outer race of the steering knuckle bearing over the sealing cover out of the bore.
Remove sealing components from the axle housing. Pull sleeve out of the axle housing.
(S) pry bar
(S) support
(S) internal puller
Assemble - Final Drive
Before starting the reassembly, install differential carrier assembly into the axle housing with a hoist and lifting device. Fasten differential carrier with hex. head screws.
NOTE: Pay attention to the installation position of the differential carrier, see marking. Cover flange facing and hex. head screws with sealing compound.
Torque limit 190 N·m
(S) adjusting screws
Cover both sealing covers with sealing compound and drive them flush mounted into the steering knuckle bearing bore. Install subsequently bearing outer races firmly against shoulder.
NOTE: Pay attention to different sizes.
(S) driver
(S) driver
(S) handle
Install sleeve flush mounted into the axle housing.
(S) driver
(S) handle
Cover shaft seal with sealing compound and install it firmly against shoulder.
(S) driver
(S) handle
Drive ring with retaining plate into the bore.
(S) driver
(S) handle
Position the steering knuckle hull (housing) over the axle housing.
Insert tapered roller bearing into the steering knuckle bearing bore, using grease and replace sealing cap.
Cover O-ring with grease and make it adhere in the king pin groove. Install king pin into the steering knuckle bearing bore.
Repeat step of figure 32 - 33 for the lower steering knuckle bearing bore.
Install both shims (value found by experience 3.0 mm) and fix them by means of cover.
Insert hub carrier into the steering knuckle hull bore and fasten with 3 hex. head screws provisionally. Fasten both bearing caps by means of hex. head screws.
NOTE: Pay attention to the installation position, see markings. Use shims of equal thickness on top and bottom.
Torque limit 400 N·m
Check rolling resistance, nominal valve 40 - 50 N·m, on the steering knuckle bearing, using torque spanner.
If the rolling resistance does not correspond to this value, modify the shims.
NOTE: Install shims of equal thickness on top and bottom.
(S) spanner
Remove hub carrier. Introduce universal shaft carefully into the axle housing and push in until the universal shaft splines have been received in the differential.
Drive sleeve into the hub carrier bore firmly against shoulder.
(S) driver
(S) handle
Cover shaft seal with sealing compound and install it firmly against shoulder.
(S) driver
(S) handle
Install ring and retaining plate into the bore.
(S) driver
(S) handle
Screw in adjusting screws, guide hub carrier carefully over universal shaft and place it against the steering knuckle housing.
(S) adjusting screws
Place anchor plate against hub carrier.
Screw in 4 socket head screws M 16x45, see arrow on top, and 2 allen-head screws M 16x50, see arrow below (on illustration).
Remove adjusting screws, install the remaining allen-head screws (M 16x55) and tighten with torque wrench.
Torque limit 295 N·m
Install wheel brake cylinder and tighten hex. head screws.
Torque limit (M 12/8.8) 86 N·m
Install brake line connection.
NOTE: Pay attention to the location (connection for brake line is showing opposite to the driving direction).
Engage both brake shoes.
Insert bolts.
NOTE: Pay attention to the radial position of the fixing bore.
Fix both bolts by means of locking screws and tighten them.
Pull all wheel studs into the hub until contact is obtained, using special device.
(S) wheel stud puller - basic set
(S) insert (M 22x1.5)
Drive bearing outer race into the hub bore.
(S) driver
(S) handle
Install tapered roller bearing and place scraper upon it.
Cover shaft seal with sealing compound and install it firmly against shoulder.
(S) driver
(S) handle
Install bearing outer race firmly against shoulder.
(S) driver
(S) handle
Place brake drum against the hub and fix it by means of 2 allen-head screws.
Torque limit 49 N·m
Guide hub with installed brake drum over the end of the hub carrier and place it firmly against shoulder.
Pay attention to the free travel of the brake drum (if required, back off brake shoes).
(S) fixing yoke
Install subsequently tapered roller bearing firmly against shoulder.
Guide internal gear over the splines of the hub carrier and place it firmly against shoulder.
Spray Molykote (sliding varnish) upon the hub carrier threads. Install the inside slotted nut with the chamfered face towards the outside.
Tighten slotted nut to about 100 N·m (gives a rolling resistance of the wheel bearing of 11 - 16 N·m). Replace lock plate and screw on the outside slotted nut with the chamfered face towards the inside.
Torque limit of the outside slotted nut 325 N·m
(S) pin spanner
Wrap string around the hub and check rolling resistance with commercial spring scale.
Rolling resistance should be 11 - 16 N·m
NOTE: For run-in bearings, reduce this value for 50%.
Secure both slotted nuts against loosening by means of lock plate.
Decrease the clearance of the brake shoe via the eccentric screw (in direction of arrow) until the brake drum can not be rotated. Then back off the screw until the brake drum rotates freely. Carry out this step for both brake shoes.
Place thrust washer with the noses (tabs) ahead against the face of the hub carrier until contact is obtained.
Assemble sun gear and fix by means of snap ring.
Assemble the planetary carrier according to the illustration (arrangement of the components).
NOTE: Heat planetary carrier bores.
| NOTICE |
|---|
Check the groove for the snap ring for wear. Also, check snap rings for wear and stress. Replace with a new one if not of new quality. |
Alignment of the Universal Shaft
Measure dimension A from flange facing planetary carrier to the contact area thrust washer.
e.g. 6.80 mm
(S) straightedge
Slide universal shaft toward the axle center and place it against shoulder. Determine dimension B from flange facing to the face of the universal shaft with a straightedge and a micrometer.
e.g. 3.80 mm
(S) straightedge
Example:
In order to obtain a required end play of 1.0 - 1.3 mm, select a thrust washer with a thickness of 2.0 mm.
Cover determined thrust washer (e.g. thickness 2.0 mm) with grease to make it adhere in the planetary carrier.
Cover flange facing with sealing compound and place planetary assembly firmly against hub.
| NOTICE |
|---|
Recess for the oil drain on the hub must be corresponding with the oil drain hole on the planetary carrier (see arrows). |
Tighten hex. head screws.
Torque limit (M 12/8.8) 86 N·m
Position special measuring device on the axle housing.
Adjust steering lock 30° on both sides and always on the wheel running the inner track.
(S) measuring device
Hold tight the washer, ring and retaining plate by means of commercial clamp (to facilitate the tie rod installation).
Fix tie rod and steering cylinder on the steering knuckle housing by means of bolts. Tighten castle nut and secure with cotter pin.
Position tie rod on the opposite side and locate it with centering pin.
(S) centering pin
Install straightedges on both wheel hubs and determine distance by means of measuring tape.
NOTE: Marks (for measurement) on the straightedges replace the wheel flange if the wheels have been removed.
Rotate both wheel hubs for 180° until the opposite position of the straightedges has been reached. Repeat measuring operation.
Adjust toe-in - nominal value 0 - 3 mm.
For this step remove centering pin, unhook tie rod and adjust toe-in by axial adjustment (rotation) of the tie-rod head.
After the adjustment, repeat step of figure 75.
(S) straightedge
Adjust both stops opposite the tie-rod side so the screw heads have contact without play.
NOTE: Torque for the nuts that hold the steering wheels in position is 550 to 600 N·m