Corresponding Model Model 70Z6 80Z6
ZF Axle Parts No. MT-L 3085 II MT-L 3095 II
This book consists of the following items. REPAIR MANUAL Lubrication and Maintenance Instructions
REPAIR MANUAL ZF – MULTITRAC MT-L 3085 II / 3095 II
5871.529.002 en
REPAIR MANUAL for ZF - Multitrac MT-L 3085 II / 3095 II IMPORTANT INFORMATION: Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit. Continuous technical upgrading of the ZF units and extensions concerning design options may require differing operations which can be carried out by qualified specialists without greater difficulties by means of the perspective views included in the corresponding spare parts lists. This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of issue of the manual. ZF Friedrichshafen AG reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice. Upon request, ZF Friedrichshafen AG will advise which edition is the latest one. Any maintenance work is to be done in accordance with ZF’s Lubrication and Maintenance Instructions (ZF-order no: 5871 529 902) and ZF’s List of Lubricants TE-ML 05!
The ZF list of lubricants is being continuously updated and can be obtained or viewed as follows: - at all ZF plants - at all ZF service organizations - Internet www.zf.com
---------------------------------------------------------------------------------------------------------------------------------
CAUTION: Observe the vehicle manufacturer’s instructions and specifications for the installation and commissioning of the unit!
ZF Friedrichshafen AG ZF Services Donaustr. 71 D - 94034 Passau Abt.: MAIP21 Copyright © ZF Friedrichshafen AG This document is protected by copyright. Complete or partial reproduction or dissemination of this document is prohibited without the consent of ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution. This document is a translation of the German original. With the reserve of technical modifications! Design level 2010/10 4. Edition 2012/01
TABLE OF CONTENTS
Chapter/Page
Preface
0/1
General
0/2 … 3
Labeling of identification plate Examples of contact patterns for the Gleason gear tooth system
0/4 0/5 … 8
Conversion table
0/9
Denomination of standard dimensions
0/10
Tightening torques for screws
0/11
TOOLS
WS/1 ... WH/5
Special tools
WS/1 ... 10
Commercial tools
WH/1 ... 5
DISASSEMBLY
1/1 ... 4/8
1.
Disassembly output and brake
2.
Disassembly axle housing
3.
Disassembly drive
3/1 … 3
4. 4.1 4.2 4.3
Disassembly differentials Disassembly multi-disk differential lock DHL-2400 Disassembly differential D-2400 Disassembly multi-disk differential lock DL-2400
4/1 … 3 4/1 … 3 4/4 … 6 4/7 … 8
REASSEMBLY
1/1 ... 7 2/1
5/1 ... 8/12
5. 5.1 5.2 5.3
Reassembly differentials Reassembly multi-disk differential lock DHL-2400 Reassembly differential D-2400 Reassembly multi-disk differential lock DL-2400
5/1 … 12 5/1 … 5 5/6 … 8 5/9 … 12
6. 6.1 6.2 6.3
Reassembly drive Determination of shim to obtain a correct contact pattern Reassembly of input pinion Determination of shim for setting of bearing rolling torque and backlash
6/1 … 9 6/1 … 2 6/2 … 4 6/5 … 8
7.
Reassembly axle housing
7/1 … 2
8.
Reassembly output and brake
8/1 … 12
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
PREFACE
This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair and maintenance work to be done on ZF units. This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both deviating work steps and differing setting and testing data. We would therefore recommend you to entrust masters and servicemen with the work on your ZF product whose practical and theoretical training is constantly updated in our training school. The Service Stations established by ZF Friedrichshafen AG all over the world offer you: 1. Permanently trained staff 2. Specified equipment, e.g. special tools 3. State-of-the-art genuine ZF spare parts
All work is done there with utmost care and reliability. In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms of the currently applicable contractual conditions. Any damage resulting from work which is done in an improper and unprofessional manner by third parties and any consequential costs incurred are excluded from this contractual liability. This shall also be applicable if other than genuine ZF spare parts are used. This manual is based on the state-of-the-art at the time of printing. It was prepared with utmost care in order to avoid errors. However, we shall not be liable for any errors in figures or descriptions.
ZF Friedrichshafen AG
5871 529 002
0/1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
GENERAL The Service Manual covers all work required for disassembly and the relating reassembly. When repairing the unit, ensure utmost cleanliness and excellent workmanship. Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids and housing parts which were installed with seals by slight blows with a plastic hammer. Use suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings, thrust washers etc. will be reinstalled. Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with worn or broken sealing lip must also be renewed. In particular, ensure that no chips or other foreign bodies remain in the housing. Check the lube oil holes and grooves regarding unhindered passage. Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation: Only a heating furnace or an electric drier is permitted for heating parts such as bearings, housings, etc.! Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.
NOTE:
CAUTION When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual. Tighten screws and nuts according to the enclosed standard table, unless otherwise specified. When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves! NEVER wash disks having organic friction linings (e.g. paper disks) since this would have an adverse effect on lining adhesion. Only dry cleaning is permitted (leather cloth).
DANGER When using detergents, observe the manufacturer’s instructions regarding their handling.
5871 529 002
0/2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Structure of the Service Manual The structure of this repair manual reflects the sequence of work steps for completely dismantling the removed unit. Tools required for carrying out the repair work are listed in the current text as well as in chapters “WS” (List of Special Tools) and “WH” (Commercial Tools). Important information on labor safety As a basic principle, the workshop carrying out the repair or maintenance of ZF units shall be fully responsible for labor safety. The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding any damage to persons and products during maintenance and repair work. Repair workshops must familiarize themselves with these regulations prior to starting any work. A suitably trained and skilled staff is required for a proper repair of these ZF products. The repair workshop shall be responsible for the training. The following safety references are used in this manual:
CAUTION
This symbol serves as a reference to special working procedures, methods, information, use of auxiliaries etc... indicated in this repair manual.
DANGER
This symbol identifies situations in which lacking care may lead to personal injury or damage to the product.
____________________________________________
NOTE:
Thoroughly study this manual before starting any tests or repairs.
NOTE:
Figures, drawings and parts in this manual do not always represent the original; they show the working procedure. Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on size and weight (not even within one and the same illustration). Carry out work according to the legend.
NOTE:
After repair work and tests, the expert staff must verify that the product is perfectly functioning again.
5871 529 002
0/3
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual
LABELING OF IDENTIFICATION PLATE
MIL-L-2105 D
05
LS/SAE 90
1 = Axle type 2 = Axle number 3 = ZF – parts list number 4 = Overall axle ratio/ version with or without ZF – multi-disk differential lock 5 = Oil grade 6 = Oil quality Note on item 6: See ZF List of Lubricants for ZF axles TE - ML 05 !
INFORMATION ON SPARE PARTS ORDERING The following information is required when ordering genuine ZF spare parts:
1. Axle type 2. Unit number 3. ZF – parts list number 4. Make and type of vehicle 5. Denomination of spare part 6. Spare parts number 7. Shipping mode NOTE: Item 1, 2 and 3 are visible on the identification plate. Please indicate all the a.m. details to avoid any mistakes in the delivery of the ordered spare parts!
5871 529 002
0/4
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Examples of contact patterns for the Gleason gear tooth system
Application: The examples of contact patterns are applicable for all bevel gear sets in MT and MS axles which have a ratio between 1.5 < i < 6. Also, the examples are only valid for ground bevel gear sets. (The examples are only partly applicable for lapped contact patterns). Ideal contact pattern: Pinion shimming h Tooth root
h
-
Convex
Heel Tooth top
+
2 approx. h 3
Toe Tooth root
-
Concave
Middle of tooth
1 h 2
Contact pattern setting: The contact patterns are viewed on the crown wheel flanks. The contact pattern must be tangent to the center of tooth flank (middle of tooth), otherwise it is too far on the tooth top or on the tooth root. The contact pattern should have a size of minimum 50% at the flank in h-direction (inspection criterion). General: By changing the pinion distance the contact pattern position is relocated in the direction of the tooth depth. Shimming in + : = reduce pinion shim thickness (contact pattern moves to the top) Shimming in - : = increase pinion shim thickness (contact pattern moves to the root) Flank glossary: Convex flank Concave flank Toe Heel
= Drive side = Coast side = Crown wheel inner side = Crown wheel outer side
Note: The following pages (0.6 … 0.8) describe three different examples of contact patterns!
5871 529 002
0/5
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual
EXAMPLE 1: Dedendum tooth position Contact pattern not o.k. Convex 1 h 2
1 h 2
Concave
The contact pattern on the convex and concave flank is too far in the root, although more than 50% of the flank in h-direction is covered. An adjustment is necessary! Feature:
On the convex flank the contact pattern has an impression at the toe / root and on the concave flank on the heel/root.
Adjustment: Add a smaller shim to the pinion!
Contact pattern o.k. Convex
1 h 2
Concave
1 h 2
The contact pattern is in the flank without bridging and a minimum of 50% of the flank in h-direction is covered. The contact pattern in the example is relatively small. However, the contact pattern has an impression on the middle of the tooth and would cover the flank optimally with a greater load (see sketch).
5871 529 002
0/6
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual
Example 2: Addendum tooth position Contact pattern not o.k. Convex 1 h 3 1 h 3
Concave
The contact pattern convex and concave is too far on the top. Also, the contact pattern is too small and is not tangent to the flank middle line. An adjustment is necessary! Adjustment:
Use a thicker pinion spacer!
Contact pattern o.k.
Convex
Concave
1 h 2
1 h 2
The convex contact pattern must be visible in the direction of the tooth center depth. Min. 50% of the flank in direction of tooth depth is covered.
5871 529 002
0/7
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual Example 3: “Line” contact pattern Contact pattern not o.k. Convex 1 ca. h 3 1 ca. h 3
Concave
The contact pattern convex and concave is too far up on the crown wheel. The contact pattern is also too small and is not tangent to the flank middle line. An adjustment is necessary! Adjustment:
Add a thicker pinion spacer!
Contact pattern o.k. Convex
1 h 2
1 h 2
Concave
The convex contact pattern must have an impression at the tooth middle line. A minimum of 50% of the tooth depth (flank) is covered. Note: An edge on the root of the tooth is allowed, this is caused by the shot peening process (see example).
5871 529 002
Shot-peening edge
0/8
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION
25.40 mm
=
1 in ( inch)
1 kg ( Kilogramm )
=
2.205 lb ( pounds )
9.81 Nm ( 1 kpm )
=
7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm )
=
1 lbf x ft ( pound force foot )
1 kg / cm
=
5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 )
=
14.233 psi (pound force per square inch lbf/in2 )
0.070 bar ( 0.071 kp/cm2 )
=
1 psi ( lbf/in2 )
1 Liter
=
4.456 Liter
=
1 Liter
=
3.785 Liter
=
1609.344 m
=
0° C ( Celsius ) 0 ° C ( Celsius )
5871 529 002
0.264 Gallon ( Imp. ) 1 Gallon ( Imp. ) 0.220 Gallon ( US ) 1 Gallon ( US ) 1 Mile ( Landmeile )
=
+ 32° F ( Fahrenheit )
=
273.15 Kelvin
0/9
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis :
längenbezogene Maße in kg/m;
flächenbezogene Maße in t/m2
Note :
linear density in kg/m;
areal density in t/m2
Nota :
Densité linéaire en kg/m;
Densité superficielle en t/m2
Begriff Unit Unité Masse Mass Mass Kraft Force Force Arbeit Work Travail Leistung Power Puissance Drehmoment Torque Couple Kraftmoment Moment (Force) Moment (Force) Druck (Über-) Pressure (Overpress) Pression (Sur-) Drehzahl Speed Nombre de Tours
5871 529 002
Formelzeichen neu New Nouveau m kg (Kilogramm)
alt old Vieux kg
Umrechnung Conversion Conversion
Bemerkungen Note Nota
F
N (Newton)
kp
1 kp = 9,81 N
A
J (Joule)
kpm
0,102 kpm = 1J = 1 Nm
P
KW (Kilowatt)
PS (DIN)
1 PS = 0,7355 KW 1 KW = 1,36 PS
T
Nm (Newtonmeter)
kpm
1 kpm = 9,81 Nm
T (Nm) = F (N) . r (m)
M
Nm (Newtonmeter)
kpm
1 kpm = 9,81 Nm
M (Nm) = F (N) . r (m)
pü
bar
atü
1,02 atü = 1,02 kp/cm2 = 1 bar = 750 torr
n
min -1
0/10
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148 Friction coefficient: µ tot.= 0.12 for screws and nuts without subsequent treatment, as well as for phosphated nuts. Tighten manually! Unless otherwise specified, the tightening torques can be taken from the following chart:
Dimension M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 Dimension M8x1 M9x1 M 10 x 1 M 10 x 1.25 M 12 x 1.25 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 18 x 2 M 20 x 1.5 M 22 x 1.5 M 24 x 1.5 M 24 x 2 M 27 x 1.5 M 27 x 2 M 30 x 1.5 M 30 x 2 M33 x 1.5 M 33 x 2 M 36 x 1.5 M 36 x 3 M 39 x 1.5 M 39 x 3 5871 529 002
Metric ISO standard thread DIN 13, page 13 8.8 10.9 2.8 4.1 5.5 8.1 9.5 14 15 23 23 34 46 68 79 115 125 185 195 280 280 390 390 560 530 750 670 960 1000 1400 1350 1900 1850 2600 2350 3300 3000 4300 Metric ISO-fine thread DIN 13, page 13 8.8 10.9 24 36 36 53 52 76 49 72 87 125 83 120 135 200 205 300 310 440 290 420 430 620 580 820 760 1100 730 1050 1100 1600 1050 1500 1550 2200 1500 2100 2050 2900 2000 2800 2700 3800 2500 3500 3450 4900 3200 4600 0/11
12.9 4.8 9.5 16.5 28 40 79 135 215 330 460 650 880 1100 1650 2250 3000 3900 5100 12.9 43 62 89 84 150 145 235 360 520 490 720 960 1250 1200 1850 1800 2550 2500 3400 3300 4450 4100 5700 5300
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
1/1 1/7
Assembly truck cpl. with tilting device 1
5870 350 000
1
1/1
Fixtures
2
5870 350 077
1
1/1
Clamping brackets
3
Chapter/Fig.
2 5870 350 075
1/1
Support
4
5870 350 125
1
1/5 8/40
Load carrying device
5
5871 529 002
5870 281 043
WS/1
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
1/7
Fixture
6
5870 350 113
Chapter/Fig.
1
1/11 8/24
Inner extractor MT-L 3085 II 7
1 5870 300 019
1/11 8/24
Eye bolt MT-L 3085 II 8
1 5870 204 073
1/11 8/24
Inner extractor
9
1 5870 300 017
1/11 8/24
Eye nut
10
1 5870 204 076
5871 529 002
WS/2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
1/12
Rapid grip
11
Chapter/Fig.
1 5873 014 016
1/12 1/24
Basic tool
12
1 5873 004 001
1/22 1/23
Resetting device
13
5870 400 001
2
1/24
Rapid grip
14
5873 014 013
1
3/1 6/19 6/24
Load carrying device
15
5871 529 002
5870 281 083
WS/3
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
Chapter/Fig.
1
3/6 6/11 6/25 6/27
1
3/6 6/11 6/25 6/27
Slotted nut wrench
16
5870 401 139
Clamping device
17
5870 240 002
3/8
Extractor
18
5870 000 065
1
3/8
Hexagon screw
19
AA00 331 360
2
3/9
Gripping device
20
5871 529 002
AA00 684 425
WS/4
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
3/9
Basic tool
21
5873 002 000
1
4/2 4/13 4/22
Rapid grip
22
5873 012 016
1
4/2 4/13 4/22
Basic tool
23
5873 002 001
1
4/2
Grab sleeve
24
5873 003 029
1
4/2
Reduction
25
5871 529 002
5873 003 011
WS/5
Chapter/Fig.
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
Chapter/Fig.
1
4/2 4/3 5/15 5/17
Pressure piece
26
5870 100 075
Locating pins (M16x1,5) 27
5870 204 040
1
5/1 5/9 5/20 5/28 5/31 5/43
5/13
Pressure piece 5870 100 069 28
1
5/13
Load cell
29
5870 700 004
1
5/16
Lifting device
30
5871 529 002
AA00 331 446
WS/6
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
6/4
Driver tool
31
5870 058 079
1
6/4
Handle
32
5870 260 004
1
6/6
Assembly fixture
33
5870 345 080
1
2 1
34
Measuring disk D / DL 2400 DHL 2400 AA00 848 434
6/16
6/16
Measuring disk DHL 2400 35
5871 529 002
AA00 848 397
WS/7
Chapter/Fig.
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
6/16
Measuring support
36
AA00 860 154
Chapter/Fig.
2
Straightedge
37
5870 200 022
1
6/21 7/2
Adjusting screws (M20) 38
5870 204 024
1
6/26
Driver tool
39
5870 048 233
1
8/1
Assembly fixture
40
5871 529 002
5870 610 010
WS/8
6/16 8/32 8/35
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
8/1
Insert (M22x1,5) 41
5870 610 002
1
8/7
Pressure ring
42
5870 506 172
1
8/8
Driver tool
43
5870 051 065
1
8/14
Fixing device
44
AA00 680 530
1
8/25
Measuring disk
45
5871 529 002
AA00 360 730
WS/9
Chapter/Fig.
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY MT-L 3085 II - 4474 052 215 / MT-L 3095 II – 4474 053 221-223 Cons. Figure No.
Designation Order No.
Qty
8/40
Adjusting screws (M18x1,5) 46
5870 204 029
1
8/42 8/43
HP pump
47
5870 287 007
1
8/42
Clutch
48
0501 207 939
1
8/42
Reduction (M18x1,5) 49
5870 950 161
1
8/42
Breather bottle
50
5870 286 072
5871 529 002
WS/10
Chapter/Fig.
1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure No.
Designation Order no.
Qty.
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
1
Universal
Magnetic stand 5870 200 055 1
Dial indicator 5870 200 057 2
Gauge blocks 5870 200 066
70 mm
5870 200 067
100 mm
3
Digital depth gauge 5870 200 072
200 mm
4 5870 200 114
300 mm
Digital caliper gauge 5870 200 109 5
5871 529 002
WH/1
150 mm
.
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure No.
Designation Order no.
Qty.
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
Torque wrench
6
5870 203 030
0.6 -6.0 Nm
5870 203 031
1.0 – 12 Nm
5870 203 032
3.0 – 23 Nm
5870 203 033
5.0 – 45 Nm
5870 203 034
10 – 90 Nm
5870 203 039
80 – 400 Nm
5870 203 016
140 – 750 Nm
5870 203 011
750 - 2000 Nm
Hot air blower 7
5870 221 500
230 V
5870 221 501
115 V
Plastic hammer 5870 280 004 8
Ø 60 mm
Substitute nylon insert 5870 280 006
Lifting strap 5870 281 026 9
5871 529 002
WH/2
.
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure No.
Designation Order no.
Qty.
Chapter/Fig
1
Universal
1
Universal
1
Universal
1
Universal
1
Universal
Lifting chain 5870 281 047 10
Pry bar 5870 345 071 11
Striker 5870 650 004 12
Set of internal pliers I1-I2-I3-I4 13
5870 900 013
Set of internal pliers I11-I21-I31-I41 90° 14
5871 529 002
5870 900 014
WH/3
.
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure No.
Designation Order no.
Qty.
Chapter/Fig
1
Universal
1
Universal
1
Universal
Set of external pliers A1-A2-A3-A4 15
5870 900 015
Set of external pliers A01-A02-A03-A04 16
90°
5870 900 016
Two-armed puller
17
5871 529 002
5870 970 001 Jaw width Throat depth 5870 970 002 Jaw width Throat depth 5870 970 003 Jaw width Throat depth 5870 970 004 Jaw width Throat depth 5870 970 006 Jaw width Throat depth 5870 970 007 Jaw width Throat depth 5870 970 026 Jaw width Throat depth 5870 970 028 Jaw width Throat depth
WH/4
80 mm 100 mm 120 mm 125 mm 170 mm 125 mm 200 mm 175 mm 350 mm 250 mm 520 mm 300 - 500 mm 250 mm 200 mm 380 mm 200 mm
.
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY
Cons. Figure No.
Designation Order no.
Qty.
Chapter/Fig
1
Universal
Three armed puller
18
5871 529 002
5870 971 001 Jaw width Throat depth 5870 971 002 Jaw width Throat depth 5870 971 003 Jaw width Throat depth 5870 971 004 Jaw width Throat depth 5870 971 005 Jaw width Throat depth 5870 971 006 Jaw width Throat depth
WH/5
85 mm 65 mm 130 mm 105 mm 230 mm 150 mm 295 mm 235 mm 390 mm 270 mm 640 mm 300 mm
.
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
ZF – MULTITRAC AXLE MT-L 3085 II / MT-L 3095 II 1.
Disassembly output and brake
Fix axle to assembly truck. (S) Assembly truck (S) Fixtures (S) Clamping brackets (S) Support
5870 350 000 5870 350 077 5870 350 075 5870 350 125
Figure 1 Before clamping the axle fully turn in the support (S)! Position axle first onto the two fixtures (S), secure with clamping brackets (S) and then unbolt the support (S) until contact with the axle is obtained!
Loosen screw plugs (3x, see Figure 2 and 3) and drain oil from the axle.
Figure 2
Figure 3
5871 529 002
1/1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Remove the breather valve (see arrow).
To avoid any damage, the breather valve must be removed when separating the output!
Figure 4 Secure the output with the lifting device (S) and loosen hexagon screws. Then separate the output assy from the axle housing. (S) Load carrying device
5870 281 043
Fix the load carrying device (S) with a wheel nut!
Figure 5 Pull stub shaft and sun gear shaft.
Pay attention to potentially releasing shim(s)!
Figure 6 Fix output to assembly truck. (S) Assembly truck (S) Fixture
Figure 7
5871 529 002
1/2
5870 350 000 5870 350 113
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Use a lever to remove the cover from the output shaft.
Figure 8 Loosen locking screws and remove the releasing cover.
Figure 9 Press planetary carrier with a two-armed puller out of the profile of the output shaft.
Figure 10 Lift the planetary carrier out of the brake housing by means of the lifting device. MT-L 3085 (planetary carrier with 3 planetary gears) (S) Inner extractor 5870 300 019 (S) Eye bolt 5870 204 073 MT-L 3095 (planetary carrier with 4 planetary gears) (S) Inner extractor 5870 300 017 (S) Eye nut 5870 204 076
Figure 11
5871 529 002
1/3
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Pull the tapered roller bearing from the planetary carrier. (S) Rapid grip (S) Basic tool
5873 014 016 5873 004 001
Figure 12 Disengage retaining ring.
Figure 13 Pull off planetary gear.
Figure 14 Lift the end plate out of the brake housing.
Figure 15
5871 529 002
1/4
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Lift the disk package out of the brake housing.
Figure 16 Loosen hexagon screws, remove releasing cover and cup spring.
Figure 17 Mount breather valve and press piston out of the brake housing by means of compressed air.
Figure 18 If necessary, remove guide ring, back-up rings and grooved rings out of the annular grooves of the brake housing (see arrows).
Figure 19
5871 529 002
1/5
For the installation position of the single parts please also refer to the following sketch!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
Figure 20 Lift the brake housing from the output shaft by means of the lifting device.
Figure 21 Version with slide ring seal Use a lever to remove the slide ring seal from the brake housing. Version with combi seal Use a lever to remove the shaft seal from the brake housing. If necessary, force out both bearing outer rings. (S) Resetting device
Figure 22
5871 529 002
1/6
5870 400 001
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Version with slide ring seal Use a lever to remove the slide ring seal from the output shaft. Version with combi seal Visually check the screening plate regarding wear marks, and if required, separate it from the output shaft. (S) Resetting device
5870 400 001
Figure 23 Pull the tapered roller bearing from the output shaft. (S) Rapid grip (S) Basic tool
Figure 24
5871 529 002
1/7
5873 014 013 5873 004 001
Repair Manual 2.
Corporate Division Off-Road Driveline Technology and Axle Systems
Disassembly axle housing
Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing.
Pay attention to releasing differential!
Figure 1 Loosen the threaded connections and remove the releasing brake tube.
Figure 2 Loosen screw neck.
Figure 3 Pull the bearing outer ring out of the bearing hole and remove the shim behind. Then remove the O-ring (see arrow).
Figure 4
5871 529 002
2/1
Repair Manual 3.
Corporate Division Off-Road Driveline Technology and Axle Systems
Disassembly input
Use the lifting device to lift the differential out of the axle drive housing. (S) Load carrying fixture
5870 281 083
Disassembly of the differential is described as of page 4/1!
Figure 1 Pull the bearing outer ring (see arrow) out of the housing hole and remove the shim behind.
Figure 2 Press piston (see arrow) out of the axle housing (see subsequent Figure) by means of compressed air.
Figure 3
Figure 4
5871 529 002
3/1
This operation is only necessary for the version with DHL!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Heat slotted nut by means of hot air blower.
Slotted nut is secured with Loctite (Type no.: 262)!
Figure 5 Loosen slotted nut and remove the shim behind. (S) Slotted nut wrench (S) Clamping device
5870 401 139 5870 240 002
Figure 6 Pull the input flange from the input pinion and use a lever to remove the shaft seal behind from the axle drive housing.
Figure 7 Press input pinion from the axle drive housing and remove the releasing tapered roller bearing. (S) Extractor (S) Hexagon screw (2x)
Figure 8
5871 529 002
3/2
5870 000 065 AA00 331 360
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Remove spacer ring and pull the tapered roller bearing from the input pinion. (S) Gripping device (S) Basic tool
AA00 684 425 5873 002 000
Figure 9 If necessary, force both bearing outer rings out of the axle drive housing.
Figure 10
5871 529 002
3/3
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
4.
Disassembly differentials
4.1
Disassembly multi-disk differential lock DHL-2400
Remove axial roller cage (arrow).
Figure 1 Pull both tapered roller bearings from the differential. Crown wheel side (S) Grab sleeve (S) Basic tool Opposite side (S) Grab sleeve (S) Basic tool (S) Reduction (S) Pressure piece
5873 012 016 5873 002 001 5873 003 029 5873 002 001 5873 003 011 5870 100 075
Figure 2 Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover. (S) Pressure piece
5870 100 075
Figure 3 Preload the housing cover/compression spring by means of the press and disengage the retaining ring. Then remove sliding sleeve and compression spring from the housing cover.
Figure 4
5871 529 002
4/1
Repair Manual
1
2
Corporate Division Off-Road Driveline Technology and Axle Systems
Remove single parts.
3 4
1 = Pressure piece 2 = Cage 3 = Lever (12x) 4 = Disk carrier 5 = Disk package
5
Figure 5 Preload differential by means of the press, loosen locking screws and housing cover.
Figure 6 Remove axle bevel gear with thrust washers from the differential housing.
Figure 7 Force out both slotted pins.
Figure 8
5871 529 002
4/2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Force out both differential axles (short) and remove the releasing spider gears with thrust washers from the differential housing.
Figure 9 Pull the differential axle (long) and remove the releasing spider gears with thrust washers from the differential housing.
Figure 10 Remove the axle bevel gear and the shim behind.
Figure 11 Press crown wheel from the differential carrier.
Figure 12
5871 529 002
4/3
Repair Manual 4.2
Corporate Division Off-Road Driveline Technology and Axle Systems
Disassembly differential D-2400
Pull both tapered roller bearings from the differential. (S) Grab sleeve (S) Basic tool
5873 012 016 5873 002 001
Figure 13 Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.
Figure 14 Preload the differential by means of the press, loosen locking screws and housing cover.
Figure 15 Remove axle bevel gear with thrust washers from the differential housing.
Figure 16
5871 529 002
4/4
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Force out both slotted pins.
Figure 17 Force out both differential axles (short) and remove the releasing spider gears with thrust washers from the differential housing.
Figure 18 Pull the differential axle (long) and remove the releasing spider gears with thrust washers from the differential housing.
Figure 19 Remove the axle bevel gear and the shim behind.
Figure 20
5871 529 002
4/5
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Press crown wheel from the differential carrier.
Figure 21
5871 529 002
4/6
Repair Manual 4.3
Corporate Division Off-Road Driveline Technology and Axle Systems
Disassembly multi-disk differential lock DL-2400
Pull both tapered roller bearings from the differential. (S) Grab sleeve (S) Basic tool
5873 012 016 5873 002 001
Figure 22 Preload the differential by means of the press, loosen locking screws and housing cover.
Figure 23 Lift the axle bevel gear with pressure ring, disk package and thrust washers out of the differential housing.
Figure 24 Remove spider shafts and axle bevel gears (see Figure) out of the differential housing.
Figure 25
5871 529 002
4/7
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Remove the second axle bevel gear.
Figure 26 Lift the pressure ring out of the differential housing and remove the disk package and thrust washers behind.
Figure 27 Press crown wheel from the differential carrier.
Figure 28
5871 529 002
4/8
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
5.
Reassembly differentials
5.1
Reassembly multi-disk differential lock DHL-2400
Mount two locating pins (S) and press the heated crown wheel onto the differential housing until contact is obtained. (S) Locating pins
5870 204 040
Figure 1 Insert thrust washer into the differential housing.
Figure 2 Insert axle bevel gear.
Figure 3 Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft (long).
Figure 4
5871 529 002
5/1
Thrust washers must be positioned with the tabs (see arrow) being located in the recesses of the differential housing!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts (short). 1
2
Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing! Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2)!
Figure 5 Fix spider shafts (short) with slotted pins.
Flush mount slotted pins!
Figure 6 Mount second axle bevel gear.
Figure 7 Fix the thrust washers into the housing cover by means of grease.
Figure 8
5871 529 002
5/2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Mount two adjusting screws (S) and insert the housing cover until contact with the differential housing is obtained. (S) Locating pins
5870 204 040
Preload the differential by means of the press and bolt with new locking screws. Tightening torque (M16/12.9)
MA = 400 Nm
Figure 9 Install compression spring onto the sliding sleeve.
Figure 10 Insert the premounted sliding sleeve into the housing cover. Preload the compression spring by means of the press and engage the retaining ring into the annular groove of the sliding sleeve.
Figure 11
Setting of disk package Premount single parts according to the adjacent sketch.
9 5
8 7 6 4
1 = Housing cover 2 = Pressure piece 3 = Cage 4 = Lever (12x) 5 = Disk carrier 6 = Pressure ring 7 = Inner disks 8 = Outer disks (optional) 9 = Snap ring
3 2 1
Figure 12
5871 529 002
5/3
For the number of disks and the disk arrangement please refer to the relating spare parts list!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Preload disk package with an axial force of F = 50 +30 KN. Then check the setting dimension „A“ = 1.05 ±0.1 mm from the collar of the differential cover to the plane face of the outer disk (see also below sketch) . (S) Pressure piece (S) Load cell
Figure 13
5870 100 069 5870 700 004
Any deviation from the specified setting dimension must be corrected with a corresponding outer disk!!
Legend to sketch:
A
A = Setting dimension = 1.05 ±0.1 mm B = Contact face To obtain a correct measuring result: The housing cover may only be supported on the contact face (B)! Ensure that the assembly fixture (S) is only supported on the disk package and not on the disk carrier (5)!
B
Figure 14 Position housing cover onto pressure piece (S, see arrow). Insert two hexagon screws into the housing cover to radially fix the disk package. (S) Pressure piece
5870 100 075
Figure 15 Position the premounted differential with the lifting device (S) onto the housing cover and preliminarily fix with hexagon screws. (S) Lifting device
Figure 16
5871 529 002
5/4
AA00 331 446
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Preload the differential by means of the press and the pressure piece (S). Then finally tighten the housing cover with hexagon screws. Tightening torque (M14/10.9) (S) Pressure piece
MA = 185 Nm 5870 100 075
Figure 17 Heat both tapered roller bearings and insert until contact is obtained.
Adjust tapered roller bearing after cooling down!
Figure 18 Fix axial roller cage (see arrow) to the sliding sleeve by means of grease.
Figure 19
5871 529 002
5/5
Repair Manual 5.2
Corporate Division Off-Road Driveline Technology and Axle Systems
Reassembly differential D-2400
Mount two locating pins (S) and press the heated crown wheel onto the differential housing until contact is obtained. (S) Locating pins
5870 204 040
Figure 20 Insert thrust washer into the differential housing.
Figure 21 Insert axle bevel gear.
Figure 22 Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft (long).
Figure 23
5871 529 002
5/6
Thrust washers must be positioned with the tabs (see arrow) being located in the recesses of the differential housing!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts (short). 1
2
Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing! Pay attention to radial installation position of the spider shafts (fixing holes, arrow 2)!
Figure 24 Fix spider shafts (short) with slotted pins.
Flush mount slotted pins!
Figure 25 Mount second axle bevel gear.
Figure 26 Fix the thrust washers into the housing cover by means of grease.
Figure 27
5871 529 002
5/7
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Mount two adjusting screws (S) and insert the housing cover until contact with the differential housing is obtained. (S) Locating pins
5870 204 040
Preload the differential by means of the press and bolt with new locking screws. Tightening torque (M16/12.9)
MA = 400 Nm
Figure 28 Attach the housing cover and preload the differential with the press. Then fix the housing cover with hexagon screws. Tightening torque (M14/10.9)
MA = 185 Nm
Figure 29 Heat both tapered roller bearings and insert until contact is obtained.
Figure 30
5871 529 002
5/8
Adjust tapered roller bearing after cooling down!
Repair Manual 5.3
Corporate Division Off-Road Driveline Technology and Axle Systems
Reassembly multi-disk differential lock DL-2400
Mount two locating pins (S) and press the heated crown wheel onto the differential housing until contact is obtained. (S) Locating pins
5870 204 040
Figure 31 Insert thrust washer into the differential housing.
Figure 32 Mount outer and inner disks in alternating order, starting with an outer disk.
The installation clearance of the internal parts is corrected by mounting outer disks with different thicknesses! The difference in thickness between the left and the right disk package must only be 0.1 mm at maximum!
Figure 33 Place the pressure ring.
Figure 34
5871 529 002
5/9
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert the axle bevel gear until contact is obtained and install the inner disks with the teeth.
Figure 35 Preassemble the differential spider and insert it into the differential housing /into the pressure ring.
Figure 36 Mount second axle bevel gear.
Figure 37 Zweiten Druckring in das Differentialgehäuse einsetzen.
Figure 38
5871 529 002
5/10
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Mount outer and inner disks in alternating order, starting with an inner disk.
The installation clearance of the internal parts is corrected by mounting outer disks with different thicknesses! The difference in thickness between the left and the right disk package must only be 0.1 mm at maximum!
Figure 39 Determine the installation clearance 0.2 … 0.7 mm Measure dimension I, from the mounting face of the differential housing to the plane face of the outer disk. Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 44.30 mm
Figure 40 Measure dimension II, from the contact face of the outer disk to the mounting face on the housing cover. Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . 43.95 mm CALCULATION EXAMPLE: Dimension I . . . . . . . . . . . . . . . . . . . . . . . . . . 44.30 mm Dimension II . . . . . . . . . . . . . . . . . . . . . . . . . . - 43.95 mm Difference = disk clearance = 0.35 mm Figure 41
5871 529 002
5/11
Any deviation from the required installation clearance is to be corrected with corresponding outer disks (s = 2.7, s = 2.9, s = 3.0, s = 3.1, s = 3.2, s = 3.3 or s = 3.5 mm), taking care that the difference in thickness between the left and the right disk package must only be 0.1 mm at maximum!
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Fix the thrust washers into the housing cover by means of grease.
Bild 42 Mount two adjusting screws (S) and insert the housing cover until contact with the differential housing is obtained. (S) Locating pins
5870 204 040
Preload the differential by means of the press and bolt with new locking screws. Tightening torque (M16/12.9)
MA = 400 Nm
Bild 43 Heat both tapered roller bearings and insert until contact is obtained.
Bild 44
5871 529 002
5/12
Adjust tapered roller bearing after cooling down!
Repair Manual 6.
Corporate Division Off-Road Driveline Technology and Axle Systems
Reassembly input
wheel or input pinion are damaged, both parts must Ifbecrown jointly replaced!
6.1
Determination of shim thickness to obtain a correct contact pattern
following measuring procedures must be carried out The with utmost accuracy! Inaccurate measurements lead to an incorrect contact pattern requiring an additional disassembly and reassembly of input pinion and differential!
Read dimension I from the axle drive housing. Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 221.10 mm
221,10
Figure 1 Read dimension II (pinion dimension). 181,0 ± 0
Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 181.00 mm
Figure 2
5871 529 002
6/1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Determine dimension III (bearing width). Dimension III e.g. . . . . . . . . . . . . . . . . . . . . . . . . . . 39.10 mm
CALCULATION EXAMPLE „A“: Dimension I. . . . . . . . . . . . . . . . . . . . . . . 221.10 mm Dimension II . . . . . . . . . . . . . . . . . . . . . . - 181.00 mm Dimension III . . . . . . . . . . . . . . . . . . . . . . - 39.10 mm Difference = shim s = 1.00 mm Figure 3 6.2
Reassembly of input pinion
Undercool the external bearing outer ring and insert it into the axle drive housing until contact is obtained. (S) Driver tool (S) Handle
5870 058 079 5870 260 004
Figure 4 Insert the determined shim e.g. s = 1.00 mm into the housing hole.
Figure 5 Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using the assembly fixture (S). (S) Assembly fixture
Figure 6
5871 529 002
6/2
5870 345 080
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Heat the tapered roller bearing and insert it into the input pinion until contact is obtained.
Figure 7 Setting of rolling torque of input pinion bearing 1.5 ... 4.0 Nm (without shaft seal) Insert spacer (e.g. s = 8.18 mm). to our experience the necessary rolling torque is According obtained when reusing the spacer which has been removed during disassembly (e.g. s = 8.18 mm)! A later check of the rolling torque, however, is absolutely necessary! Figure 8 Insert the preassembled input pinion into the axle drive housing and insert the heated tapered roller bearing until contact is obtained.
Figure 9 Press the protection plate onto the input flange (see arrow) until contact is obtained. not fit the shaft seal until the contact pattern has been Dochecked!
Figure 10
5871 529 002
6/3
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert input flange and fix it by means of disk and slotted nut. Tightening torque (S) Slotted nut wrench (S) Clamping device
MA = 1200 Nm 5870 401 139 5870 240 002
Preliminarily mount slotted nut without Loctite! While tightening rotate the input pinion several times in both directions! Figure 11 Check rolling torque (1.5 ... 4.0 Nm without shaft seal). installing new bearings try to achieve the upper value When of the rolling torque! In case of deviations from the necessary rolling torque correct with a corresponding spacer (Figure 8, page 6/3) as specified below! Insufficient rolling torque install thinner spacer ring Excessive rolling torque install thicker spacer ring! Figure 12 Grease O-rings (2x, see arrows) and insert them into the annular grooves of the piston. Operation Figure 13 and 14 is only necessary for version with DHL!
Figure 13 Insert piston (see arrow) into the bearing housing until contact is obtained.
Figure 14
5871 529 002
6/4
Repair Manual 6.3
Corporate Division Off-Road Driveline Technology and Axle Systems
Determination of shims for setting of bearing rolling torque (differential housing) and backlash (bevel gear set)
shims must be determined by means of the crown Required wheel deviation read (deviation/test dimension), the deviation of the block gauge and the corresponding data in the following tables! Read crown wheel deviation. +/- 0
101
The test dimension „101“ is stamped into the crown wheel rear side. If no – or + deviation is indicated, this value corresponds to the actual value ”0” in the table below. Any – or + deviation of the test dimension caused by production is also marked on the crown wheel rear side (e.g. - 10 or - 20 or 10).
Figure 15
Determine deviation of block gauge „C“. D / DL 2400 HK Block gauge = 361 mm DHL 2400 HK Block gauge = 390.33 mm Insert bearing outer ring into the measuring disc (S, arrow 1). (S) Measuring disc
AA00 848 434
Place differential into the bearing outer ring and put on the upper bearing outer ring. Position the differential exactly by turning the differential and the upper bearing outer ring in both directions several times (rolling-in). Put on the measuring disc (S, arrow 2) and determine the deviation of block gauge „C“. (S) Measuring disc (D / DL 2400) AA00 848 434 (S) Measuring disc (DHL 2400) AA00 848 397 (S) Measuring support AA00 860 154 (S) Straightedge 5870 200 022 Figure 16 Legend to sketch: C = Block gauge D / DL 2400 HK = 361 mm DHL 2400 HK = 390.33 mm 1 = Axle housing 2 = Shim (crown wheel side) 3 = Shim (diff. carrier side) 4 = Axle housing
C
1
3
2 4
Figure 17
5871 529 002
6/5
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
11 to 20
Shim B (Diff. carrier side)
0.70 0.80 0.90 1.00 0.60 0.70 0.80 0.90
Shim A (Crown wheel side)
1.30 1.20 1.10 1.00 1.30 1.20 1.10 1.00
Crown wheel Deviation
-0.20 -0.10 0.00 0.10 -0.20 -0.10 0.00 0.10
Dimension C
1 to 10
Shim B (Diff. carrier side)
0.80 0.90 1.00 1.10 0.70 0.80 0.90 1.00
Shim A (Crown wheel side)
1.40 1.30 1.20 1.10 1.40 1.30 1.20 1.10
Crown wheel Deviation
-0.20 -0.10 0.00 0.10 -0.20 -0.10 0.00 0.10
Dimension C
Shim B (Diff. carrier side)
-9 to 0
Shim A (Crown wheel side)
-19 to -10
Crown wheel Deviation
Dimension C
Shim table D / DL 2400 HK - Block gauge: 361 mm
21 to 30
-0.20 -0.10 0.00 0.10
1.20 1.10 1.00 0.90
0.60 0.70 0.80 0.90
5871 529 002
5 to 14
6/6
Shim B (Diff. carrier side)
0.70 0.80 0.90 1.00 0.70 0.80 0.90 1.00
Shim A (Crown wheel side)
1.30 1.20 1.10 1.00 1.20 1.10 1.00 0.90
Crown wheel Deviation
-0.20 -0.10 0.00 0.10 -0.20 -0.10 0.00 0.10
Dimension C
-5 to 4
Shim B (Diff. carrier side)
0.80 0.90 1.00 1.10 0.80 0.90 1.00 1.10
Shim A (Crown wheel side)
1.40 1.30 1.20 1.10 1.30 1.20 1.10 1.00
Crown wheel Deviation
-0.20 -0.10 0.00 0.10 -0.20 -0.10 0.00 0.10
Dimension C
Shim B (Diff. carrier side)
-15 to -6
Shim A (Crown wheel side)
-25 to -16
Crown wheel Deviation
Dimension C
Shim table DHL 2400 HK - Block gauge: 390.33 mm
15 to 24
-0.20 -0.10 0.00 0.10
1.20 1.10 1.00 0.90
0.60 0.70 0.80 0.90
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert the determined shim (e.g. s = 0.9 mm) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained.
Figure 18 Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing. (S) Load carrying device
5870 281 083
Figure 19 Insert the determined shim (e.g. s = 1.1 mm) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained.
Figure 20 Mount two locating pins (S) and bring the axle housing into contact position with the axle drive housing by means of the lifting device. (S) Locating pins
5870 204 024
Then preliminarily fix the axle housing with 4 hexagon screws. Tightening torque (M20/10.9)
MA = 560 Nm
Figure 21
Preliminarily mount the axle housing without O-ring!
5871 529 002
6/7
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Leakage test of lock Pressurize the lock (p = 1 bar), close shut-off valve and remove air line.
No noticeable pressure loss is allowed to occur within 10 sec!
This operation is only necessary for version with DHL! Figure 22 By rotating the input flange, roll crown wheel over the input pinion in both directions several times. Then remove the axle housing again and lift the differential out of the axle drive housing. Compare the obtained contact pattern with contact pattern examples Page 0/5 … 0/8. In case of any contact pattern deviation, a measuring error was made when determining the shim (Figure 5, page 6/2), which must be corrected by all means!
Figure 23
After the contact pattern check insert the differential again into the axle drive housing. (S) Load carrying device
5870 281 083
Figure 24 Reassembly of shaft seal (Figure 25 … 27) Loosen the slotted nut and pull the input flange from the input pinion. (S) Slotted nut wrench (S) Clamping device
Figure 25
5871 529 002
6/8
5870 401 139 5870 240 002
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Mount the shaft seal with the seal lip showing to the oil chamber. (S) Driver tool
5870 048 233
exact installation position of the shaft seal is obtained The when using the specified driver tool (S)! Wet the outer diameter of the shaft seal with spirit directly before installation and fill the space between seal and dust lip with grease! Figure 26 Insert input flange and finally tighten by means of disk and slotted nut. Tightening torque (S) Slotted nut wrench (S) Clamping device
MA = 1200 Nm 5870 401 139 5870 240 002
Cover the thread of the slotted nut with Loctite (Type no.: 262)! Figure 27
5871 529 002
6/9
Repair Manual 7.
Corporate Division Off-Road Driveline Technology and Axle Systems
Reassembly axle housing
Grease O-ring (see arrow) and insert it into the axle housing.
Figure 1 Mount two locating pins (S) and bring the axle housing into contact position with the axle drive housing by using the lifting device. Then fix the axle housing by means of hexagon screws. Tightening torque (M20/10.9) (S) Locating pins
MA = 560 Nm 5870 204 024
After assembling the axle housing secure the axle with clamping brackets (S)!) Figure 2 Mount fitting. Tightening torque
MA = 36 Nm
Figure 3 Grease O-ring and insert it into the annular groove of the brake tube (see arrow).
Figure 4
5871 529 002
7/1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Mount brake tube with threaded connection and hexagon nut (see arrow). Tightening torque
MA = 100 Nm
Figure 5 Provide screw plug with a new O-ring and fit it. Tightening torque
Figure 6
5871 529 002
7/2
MA = 50 Nm
Repair Manual 8.
Corporate Division Off-Road Driveline Technology and Axle Systems
Reassembly output and brake
Pull in wheel stud into the output shaft until contact is obtained.
(S) Wheel stud puller - basic tool 5870 610 010 (S) Insert (M22x1.5) 5870 610 002 tool (S) may only be used for repair solution when Special exchanging individual wheel studs with mounted output shaft! When using a new output shaft, mount the wheel studs with the press. Figure 1 Heat tapered roller bearing and insert it into the output shaft until contact is obtained.
Figure 2 Version with slide ring seal Figure 3 … 4 Wet O-ring of slide ring seal and locating hole with spirit. Snap new slide ring seal (part 1) into the output shaft. Then mount new slide ring seal (part 2) accordingly into the brake housing. the installation position of the seal please also refer to For sketch 12, page 8/4! Figure 3 The surface of the slide ring seal may not have any grooves, scratches or other types of damage! Take care that the sealing surface is parallel to the housing face! The O-rings must be mounted evenly into the locating hole and must not bulge out of the hole! Risk of injury - Metal rings have extremely sharp edges! Wear protective gloves!
Figure 4
5871 529 002
8/1
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained.
Figure 5
1
Version with combi seal Figure 6 … 8
2
The adjacent sketch shows the installation position of the combi seal.
3
1 = Output shaft 2 = Brake housing 3 = Combi seal consisting of:
a
a = Shaft seal b = Screening plate
b Figure 6 Heat slide bushing and position it at the collar of the output shaft. Then position slide bushing with a pressure ring (S). (S) Pressure ring
5870 506 172
exact installation position is obtained when using the The specified pressure ring (S)!
Figure 7 Insert shaft seal into the brake housing. (S) Driver tool
5870 051 065
exact installation position is obtained when using the The specified driver tool (S)! Pay attention to installation position (see also Figure 6)! Wet the outer diameter of the shaft seal with spirit right before the assembly! Figure 8
5871 529 002
8/2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert the premounted brake housing by means of the lifting device over the output shaft until contact is obtained.
Before clamping the seal rings (slide ring seal) to installation dimension, clean the sliding surfaces and apply an oil film. We recommend to use a leather cloth soaked with oil!
Figure 9 Insert back-up rings and grooved rings into the annular grooves of the brake housing (see arrows). attention to the installation position; please also refer to Pay sketch 12, page 8/4!
Figure 10 Clean the annular groove of the brake housing with spirit. Then insert the guide ring into the annular groove (see also the following sketch) and fix it with Loctite (type no.: 415) at its extremities (see arrows). full circumference of the guide ring must be in an exact The contact position! Upon installation the orifice of the guide ring must show upwards (12 o’clock)! Figure 11
5871 529 002
8/3
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Legend to sketch: 1 = Brake housing 2 = Guide ring 3 = Back-up ring 4 = Grooved ring 5 = Grooved ring 6 = Back-up ring 7 = Slide ring seal 8 = Output shaft
Figure 12 Flush-mount the slotted pins (6x) into the holes of the piston.
Figure 13 Insert the piston into the brake housing and carefully install with the fixing device (S) until contact is obtained. (S) Fixing device
AA00 680 530
oil seal surface of piston/back-up rings, grooved Sufficiently rings and guide ring (W-10 oils to be used)!
Figure 14
5871 529 002
8/4
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert disk and cup spring with the convex side showing upwards into the piston.
Figure 15 Insert cover and fix it by means of hexagon screws. Tightening torque (M8/10.9)
MA = 34 Nm
Figure 16 Mount outer and inner disks. the number of disks and the disk arrangement please For refer to the relating spare parts list!
Figure 17 Insert end plate.
Figure 18
5871 529 002
8/5
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Press stop bolt into the planetary carrier until contact is obtained.
1
Legend to sketch: 1 = Stop bolt 2 = Planetary carrier
2
Figure 19 Illustration shows single parts of planetary gear.
1
1 = Cylindrical roller bearing 2 = Packaging sleeve 3 = Snap ring 4 = Planetary gear
2 3 4
gear can only be supplied as component with Planetary premounted cylindrical roller bearing!
Figure 20 Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier (downwards) until contact is obtained.
Adjust bearing inner rings after cooling down! Then fix planetary gears by means of retaining rings.
Figure 21 Heat tapered roller bearing and install it to the planetary carrier until contact is obtained.
Figure 22
5871 529 002
8/6
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti-corrosive agent Weicon Anti Size (ZF-order no.: 0671 196 001). 1 2
Use 18 gr Weicon Anti Size on each output side!
Figure 23 Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device into the teeth of the output shaft.
MT-L 3085 (planetary carrier with 3 planetary gears) (S) Inner extractor 5870 300 019 (S) Eye bolt 5870 204 073 MT-L 3095 (planetary carrier with 4 planetary gears) (S) Inner extractor 5870 300 017 (S) Eye nut 5870 204 076
Figure 24
Setting of gap width output shaft / planetary carrier Bring planetary carrier with measuring disk (S) and three old locking screws, which were removed during disassembly, into contact position. Tightening torque
MA = 200 Nm
(S) Measuring disk
AA00 360 730
Figure 25 Pivot output 180° and measure gap width from the output shaft to the planetary carrier (see also subsequent sketch). Gap width e.g. . . . . . . . . . . . . . . . . . . . . . . 0.21 mm Then remove the locking screws and the measuring disk again.
Figure 26
5871 529 002
8/7
Corporate Division Off-Road Driveline Technology and Axle Systems
Repair Manual Legend to sketch: 1 = Planetary carrier 2 = Output shaft X = Gap width
X
1 2
Figure 27 Select the cover (optional) on the basis of the following table. Determined gap width (Delta) 0.30 … 0.20 mm 0.199 … 0.14 mm 0.139 … 0.02 mm
Offset to be used on the cover 0.13 ±0.01 mm 0.07 ±0.01 mm 0.0 mm
ZF-Order no. 4474 353 172 4474 353 172 4474 353 115
4474 353 172 has an offset of 0.07 mm on one side and Cover an offset of 0.13 mm on the other side! Offset 0.13 mm is visually marked with an annular groove (see arrow)!
Figure 28
Insert the cover with the offset e.g. 0.07 mm showing to the planetary carrier and tighten with new locking screws. using the cover with offset 0.07 mm, the groove When (Figure 28) must be visible when the cover is installed! Tighten locking screws successively with a tightening torque of 200 Nm! Then retighten the locking screws successively with a tightening torque of 500 Nm! Figure 29 Install O-ring (see arrow 1) to the cover. Then wet contact face (arrow 2) with Terostat MS 9360 (ZForder no.: 0666 690 171)! 2
Use new cover and O-ring! Pay attention to curing period Terostat > 24 hours!
1 Figure 30
5871 529 002
8/8
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Insert the cover into the output shaft until contact is obtained.
Figure 31 Set the axial play of the sun gear shaft 0.5 ... 2.0 mm Determine dimension I, from the mounting face of the brake housing to the front face of the stop bolt. Dimension I e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 19.75 mm (S) Gauge blocks (S) Straightedge
5870 200 066 5870 200 022
Figure 32 Insert stub shaft into the teeth of the axle bevel gear until contact is obtained.
Pay attention to the installation position; mount the stub shaft with the long teeth showing to the differential!
Bild 33 Insert the sun gear shaft until contact is obtained.
Figure 34
5871 529 002
8/9
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing. Dimension II e.g. . . . . . . . . . . . . . . . . . . . . . . . . . 17.15 mm (S) Straightedge
5870 200 022
Figure 35 CALCULATION EXAMPLE: Dimension I . . . . . . . . . . . . . . . . . . . . . . . . . . 19.75 mm Dimension II . . . . . . . . . . . . . . . . . . . . . . . . . . - 17.15 mm Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60 mm Required axial play e.g. . . . . . . . . . . . . . . . . . - 1.00 mm Difference = shim e.g. s = 1.60 mm
Insert sun gear shaft into the planetary carrier.
Figure 36 Fix determined shim(s) e.g. s = 1.60 mm with grease into the sun gear shaft.
Figure 37
5871 529 002
8/10
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Fix O-ring (see arrow) with grease into the countersink of the brake housing
Figure 38 Grease O-ring (see arrow) and install it to the axle housing.
Figure 39 Mount two adjusting screws (S) and use the lifting device to bring the output into contact position with the axle housing. Then fix the output by means of hexagon screws. Tightening torque (M18/10.9) (S) Adjusting screws (M18x15) (S) Load carrying device
MA = 390 Nm 5870 204 029 5870 281 043
Fix load carrying device (S) with wheel stud! Figure 40 Mount breather (see arrow).
Figure 41
5871 529 002
8/11
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
Check brake hydraulics for leakages starting the test, completely breathe the brake Before hydraulics! Then pressurize the brake temporarily (5x) with p = 100 bar max! High-pressure test: Build up test pressure p = 100 -10 bar max. and close connection to HP pump via shut-off valve. A pressure drop of max. 2 % (2 bar) is permissible during a 5-minute testing time!
Figure 42
Low-pressure test: Reduce test pressure p = 5 bar and close shut-off valve! No pressure drop is allowed during a 5-minute testing time! Test media: Engine oils SAE 10-W corresponds to MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE, ATF-oils type A, Suffic A Dexron of II D. (S) HP pump (S) Clutch (S) Reduction (M18x1.5) (S) Oil collector bottle
5870 287 007 0501 207 939 5870 950 161 5870 286 072
Check operability of DHL Build up pressure p = 20 bar max. and close connection to HP pump via shut-off valve. Lock on: When rotating the input flange, both outputs must have the same direction of rotation. Lock off: When rotating the input flange one side has no movement or has the opposite direction of rotation. Figure 43 to putting the axle into operation, fill it with oil Prior according to the related lubrication and maintenance instructions (5871 529 902)!
5871 529 002
8/12
Order no.: 5871 529 902
Lubrication and Maintenance Instructions ZF - MULTITRAC MT-L 3085 II / 3095 II
ZF Passau GmbH Donaustr. 25 - 71 D- 94034 Passau
Preface This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be done on ZF units. Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal may require both deviating operations and differing setting and testing data. These lubrication and maintenance instructions are based on the unit’s state-of-the-art at the time of printing. They were prepared with utmost care in order to avoid errors. ZF Passau GmbH, however, shall not be liable for any possible errors in figures or descriptions. ZF Passau GmbH reserves the right to replace these lubrication and maintenance instructions by a successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise, which edition is the latest one. The owner and the user shall be responsible for complying with the safety instructions and for implementing the maintenance work according to the specified guidelines. ZF Passau GmbH shall not be liable for any incorrect installation, improper handling, insufficient maintenance, improperly and incompetently performed work and any consequential damage resulting thereof. It is imperative to observe the relevant instructions and manuals of the vehicle manufacturer. Important information regarding technical reliability and operational safety are highlighted by the following symbols:
CAUTIION DANGER
This symbol serves as a reference to special working procedures, methods, information, use of auxiliaries etc... indicated in this repair manual.
This symbol identifies situations in which lacking care might lead to personal injury or damage to the product.
ZF Passau GmbH Donaustr. 25 - 71 94034 Passau Abt.: ASGI Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted! Subject to technical modifications! Design Level
2010/10
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
LUBRICATION AND MAINTENANCE INSTRUCTIONS FOR ZF-AXLES MT-L 3085 II / 3095 II 1.
Oil grade:
ZF List of Lubricants TE-ML 05 are authorized for ZF axles MT-L 3085 II / 3095 II.. The list of lubricants is being continuously updated and can be obtained or viewed as follows: - at all ZF plants - at all ZF service organizations - Internet http://www.zf.com/
2.
Oil change:
Precondition for a correct oil change is the horizontal installation position of the axle in every direction. Place the vehicle in a horizontal position. Clean all drain plugs, filler plugs and level check plugs carefully prior to open them. Oil drain only immediately after a longer driving time! 4
4
2 3 1 2
Legend: 1 = Oil drain hole M36x1.5 axle drive housing 2 = Oil drain hole M24x1.5 axle housing 3 = Oil filler hole M36x1.5 4 = Brake breather
5871 529 902
1
Repair Manual 2.1
Corporate Division Off-Road Driveline Technology and Axle Systems
Oil drain:
Loosen oil drain plugs 1 and 2 and drain oil.
2.2
Oil filling:
Fit oil drain plugs 1 and 2 with new O-ring and install them. Tightening torque . . . . . MA = 50 Nm Fill up oil until overflow on the oil filler/level check plug (3). Filling quantity approx. 35 liters.
2.3
Check:
Check oil level after some minutes and refill until the specified level is reached and remains constant. Fit oil filler / level check 3 with new O-ring and install it. Tightening torque . . . . . MA = 50 Nm
3.
Oil change intervals:
In this connection see specifications in the ZF list of lubricants TE-ML 05.
4.
Oil level check:
Check oil level every month, in particular, however, when a vehicle has been put into service with new or repaired axles or axle parts.
5.
Breather:
Prior to initial operation and when changing the oil within the oil change interval, clean breather and check its operability.
6.
Brake:
The following oils are authorized for the pneumatic-hydraulic brake actuation, or actuated via accumulator system 1. Engine oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE 2. ATF – oils type A, Suffic A, Dexron of II D
5871 529 902
2
Repair Manual
Corporate Division Off-Road Driveline Technology and Axle Systems
CARRY OUT WEAR MEASUREMENT ON THE MULTI DISK BRAKE
Caution: Make measurement of lining wear at least once per year, in particular, however, in case of modified braking behaviour, like:
• Brake noises • Reduced braking power • Changed deceleration • Changed brake oil level • Changed braking pressure
Wear measurement – multi-disk brake (Figure 1 and 2): A wear measurement has to be made on both output sides. Remove screw plug, actuate brake and determine Dimension X acc. to Figure 1 and 2 by means of feeler gauge. Dimension X corresponds with thickness of inner clutch disc on the piston side. Fig. 1 ATTENTION: Version with paper discs : If Dim. X < 4,0 mm, the lined discs on both output sides have to be replaced! Version with sinter discs: If Dim. X < 3,5 mm, the lined discs on both output sides have to be replaced!
“X”
Then provide the level plug with a new O-ring and install it! Tightening torque . . . . . . . . . . . . MA = 50 Nm Fig. 2
5871 529 902
3