Disassembly/Assembly Manual

Axle

Models
TH514, TH417,
TH514C,
TH417C
S/N TBW00100 & After
S/N TBT00100 & After
S/N MWC00150 & After
S/N KKW00150 & After
S/N RRJ00150 & After
S/N RRW00150 & After

31200455
UENR6253-03

Revised
July 15, 2014
 EFFECTIVITY PAGE

August 8, 2008 - A - Original Issue Of Manual

November 5, 2012 - B - Update 2.7.2, page 2-8
January 22, 2014 - C - Update Front Cover to include TH514C & TH417C.
July 15, 2014 - D - Revised Front Cover.

31200455 a
 EFFECTIVITY PAGE

b 31200455
 SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Recommendations for Repair Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Technical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.7 Component Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.8 Tightening Torques and Sealants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Section 3
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Oil Change and Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4 Grease in Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Section 4
Disassembly/Assembly/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Epicyclic reduction gear group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Wheel Hub Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4 Parking Brake Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.5 Flange Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.6 Trunnions Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.7 Brake Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.8 Axle Beam Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.9 Differential Support Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.10 Differential Group Limited Slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.11 Differential Group - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4.12 Pinion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.13 Toe-in/steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.14 Testing After Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

Section 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
31200455 i
Section Subject Page

ii 31200455
 Section 1
Safety Practices

1.1 INTRODUCTION 1.2 DISCLAIMER

This service manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and The manufacturer reserves the right to make changes
equipment reliability. and improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & MAINTENANCE
provide directions for meeting every possible contingency MANUAL
during operation, maintenance, or testing. When additional
information is desired consult the local Caterpillar dealer. The mechanic must not operate the machine until the
Operation & Maintenance Manual has been read &
Many factors contribute to unsafe conditions: carelessness,
understood, training has been accomplished and
fatigue, overload, inattentiveness, unfamiliarity, even
operation of the machine has been completed under the
drugs and alcohol, among others. For optimal safety,
supervision of an experienced and qualified operator.
encourage everyone to think, and to act, safely.
An Operation & Maintenance Manual is supplied with
Appropriate service methods and proper repair
each machine and must be kept in the manual holder
procedures are essential for the safety of the individual
located in the cab. In the event that the Operation &
doing the work, for the safety of the operator, and for the
Maintenance Manual is missing, consult your local
safe, reliable operation of the machine. All references to
Caterpillar dealer before proceeding.
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction.
Supplementary information is available from the
manufacturer in the form of Service Bulletins, Service 1.4 DO NOT OPERATE TAGS
Campaigns, Service Training Schools, the service
website, other literature, and through updates to the Place Do Not Operate Tags on the ignition key switch and
manual itself. the steering wheel before attempting to perform any
service or maintenance. Remove key and disconnect
battery leads.

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Safety Practices

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
DANGER the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.

DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
WARNING indicates a potentially hazardous situation is properly attached.
which, if not avoided, could result in death or serious NEVER stand or otherwise become positioned under a
injury. suspended load or under raised equipment. The load or
equipment could fall or tip.
CAUTION DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
CAUTION indicates a potentially hazardous situation HAND TOOLS: Always use the proper tool for the job;
which, if not avoided, may result in minor or moderate keep tools clean and in good working order, and use
injury. special service tools only as recommended.

1-2 31200455
 Safety Practices

1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
HOUSEKEEPING: Keep the work area and operator’s
injury. To prevent personal injury, NEVER remove the
cab clean, and remove all hazards (debris, oil, tools, etc.).
radiator cap while the cooling system is hot. Wear safety
FIRST AID: Immediately clean, dress and report all injuries glasses. Turn the radiator cap to the first stop and allow
(cuts, abrasions, burns, etc.), no matter how minor the pressure to escape before removing the cap completely.
injury may seem. Know the location of a First Aid Kit, and Failure to follow the safety practices could result in death
know how to use it. or serious injury.
CLEANLINESS: Wear eye protection, and clean all FLUID FLAMABILTITY: DO NOT service the fuel or
components with a high-pressure or steam cleaner hydraulic systems near an open flame, sparks or smoking
before attempting service. materials.
When removing hydraulic components, plug hose ends NEVER drain or store fluids in an open container. Engine
and connections to prevent excess leakage and fuel and hydraulic fluid are flammable and can cause a
contamination. Place a suitable catch basin beneath the fire and/or explosion.
machine to capture fluid run-off.
DO NOT mix gasoline or alcohol with diesel fuel. The
Check and obey all Federal, State and/or Local mixture can cause an explosion.
regulations regarding waste storage, disposal and
PRESSURE TESTING: When conducting any test, only
recycling.
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
1.6.4 Operational Hazards manner, and make changes or repairs as indicated by the
ENGINE: Stop the engine before performing any service test procedure to achieve the desired result.
unless specifically instructed otherwise. LEAVING MACHINE: Lower the forks or attachment to
VENTILATION: Avoid prolonged engine operation in the ground before leaving the machine.
enclosed areas without adequate ventilation. TIRES: Always keep tires inflated to the proper pressure
SOFT SURFACES AND SLOPES: NEVER work on a to help prevent tipover. DO NOT over-inflate tires.
machine that is parked on a soft surface or slope. The NEVER use mismatched tire types, sizes or ply ratings.
machine must be on a hard level surface, with the wheels Always use matched sets according to machine
blocked before performing any service. specifications.
FLUID TEMPERATURE: NEVER work on a machine MAJOR COMPONENTS: Never alter, remove, or
when the engine, cooling or hydraulic systems are hot. substitute any items such as counterweights, tires,
Hot components and fluids can cause severe burns. batteries or other items that may reduce or affect the
Allow systems to cool before proceeding. overall weight or stability of the machine.
FLUID PRESSURE: Before loosening any hydraulic or BATTERY: DO NOT charge a frozen battery.Charging a
diesel fuel component, hose or tube, turn the engine frozen battery may cause it to explode. Allow the battery
OFF. Wear heavy, protective gloves and eye protection. to thaw before jump-starting or connecting a battery
NEVER check for leaks using any part of your body; use charger.
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under
1.7 SAFETY DECALS
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause Check that all safety decals are present and readable on
infection, gangrene and other serious personal injury. the machine. Refer to the Operation & Maintenance
Relieve all pressure before disconnecting any Manual supplied with machine for information.
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an

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Safety Practices

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1-4 31200455
 Section 2
General Information and Specifications

2.1 GENERAL • Do not damage the seals while assembling the

shaft.
The machine should be checked and/or repaired only by
O-rings
qualified technicians, acquainted with its features and
well aware of all safety instructions. • Lubricate adequately before inserting them at the
right place and avoid o-ring rolling while inserting
Before performing any operation, it is advisable to carry
the shaft.
out unit cleaning accurately by removing oil/ grease
encrustations and accumulation. Adjusting shims
All disassembled mechanical parts must be cleaned • Use appropriate adjusting shims and measure
accurately with suitable products to avoid possible each one separately.
damage. Parts should be replaced if damaged, worn out,
• Complete group measurement or stampings on
cracked, seized, etc. as they could affect proper working.
the shims are not always a reliable: check.
Rotating parts (bearings, gears, shafts) and that of
hardware/fasteners (O-Ring, oil seals) should be Bearings
examined carefully since they are subject to major stress, • Its advisable to heat up bearings to 80°C - 90°C
wearing and ageing. before assembling them onto their respective
We highly advise to replace tightening parts during every shafts or to cool them (dry ice) before inserting
teardown or repair. them into corresponding bore.

If one part of the bevel gear set is replaced, the other part • Always use suitable extractors to remove the
should be replaced also. bearings. Before reassembling the bearings,
clean, check and lubricate them.
Use appropriate spare parts, nuts and bolts to avoid any
problems. Also, use metric tools for metric nuts and bolts Split pins
and Imperial tools for the others. • Before assembling elastic pins, make sure the
Some operations are destructive for removed notch is oriented towards the stressing force.
components. • Spiral elastic pins do not need orientation.
Careful reading of and a thorough understanding of these
Sealing
instructions will avoid damage to other components.
• Use sealing as advised by specifications. Ensure
2.2 RECOMMENDATIONS FOR REPAIR that parts to be sealed are clean, dry and com-
pletely grease free.
OPERATIONS
Oil drain
Before starting any disassembly and assembly opera- • Before disassembly, oil should be drained out.
tions, read carefully the following recommendations.
Cleaning
Shafts seals
• Wash all moving parts (gears, bearings, etc.)
Respect the following recommendations during shaft
carefully with diesel fuel or kerosene.
seal assembly:
• Avoid gasoline and watery alkaline solutions. Do
• Clean shaft very carefully and ensure that the not wash with steam or hot water, since it is diffi-
part in contact with the shaft seal is not dam- cult to eliminate surface humidity.
aged, cut or out of roundness.
• Dry all parts with a rag or air jet to avoid scratch-
• Assemble the seals so the lip is fitted towards the ing from abrasive residuals.
oil side.
• All surfaces should be covered with lubricant to
• Lubricate seal lips (use oil) and fill 3/4 of seal protect them from future oxidation.
cavity with grease.
• Use appropriate drivers. Do not use a hammer
directly on the seals.

31200455 2-1
General Information and Specifications

Checks 2.2.1 Symbols used in disassembly/

• Examine accurately all bearings, external rings assembly/adjustment procedures
which may be still stuck in their position and pivot
pins on which rolls rotate. Replace those which
are worn out or damaged.
• Gears should not be spoiled and teething should
not be excessively worn out. Teeth smoothing
should not be deteriorated.
• Check all grooves: assure that they are not worn
out or damaged.
• Replace spoiled parts with original spare parts.
• Replace seals on rotating shafts, before reas-
sembly.
Ends of flanges and tools
• Be careful when hammering tool or flange ends,
in order to avoid jeopardizing functionality and
integrity of either the tools or the components on
which you are operating.
Lubricant Use
• In order to lubricate the manufacturer axles cor-
rectly and to reach the exact operation tempera-
ture, it is important to use the recommended
lubricants (see 2.8), keeping their level constant
as indicated in this manual.

2-2 31200455
 General Information and Specifications

2.3 PRODUCT IDENTIFICATION

Axle Tag

2.4 MEASUREMENTS
This manual indicates all measurements in the
International System (SI). Use the conversion table
shown below to convert Imperial Measurement.

31200455 2-3
General Information and Specifications

2.5 GENERAL DESCRIPTION

The axles described in this manual consist mainly of the

groups shown above.

• WHEEL HUB: wheel support parts containing the • DIFFERENTIAL SUPPORT: differential housing with
epicyclic gears ring bevel gear for adjusting system
• EPICYCLIC REDUCTION GEAR: planetary carrier • DIFFERENTIAL: differential parts with ring bevel
with reduction/transmission parts gear
• AXLE BEAM TRUMPET: load-bearing shell • PINION: pinion with adjusting and supporting parts
structure of the axle
• PARKING BRAKE: parking brake parts and brake
• BRAKE: brake parts and brake shell structure, support structure
including the parking brake parts and brake support
structure • TRUNNIONS: trunnion parts to secure axle to the
vehicle.
• STEERING CYLINDER: steering cylinder parts with
adjusting system components

2-4 31200455
 General Information and Specifications

2.6 TECHNICAL FEATURES

31200455 2-5
General Information and Specifications

2-6 31200455
 General Information and Specifications

2.7 COMPONENT SPECIFICATIONS

2.7.1 Sensor Specifications

31200455 2-7
General Information and Specifications

2.7.2 Brake Disks Typical Data

2.7.3 Limited Slip Differential Disks

Specifications

2-8 31200455
 General Information and Specifications

2.7.4 Front Axle

Main Dimensions (mm)

31200455 2-9
General Information and Specifications

2.7.5 Rear Axle

Main Dimensions (mm)

2-10 31200455
 General Information and Specifications

2.8 TIGHTENING TORQUES AND

SEALANTS

31200455 2-11
General Information and Specifications

2-12 31200455
 General Information and Specifications

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General Information and Specifications

2-14 31200455
 General Information and Specifications

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General Information and Specifications

This Page Intentionally Left Blank

2-16 31200455
 Section 3
Troubleshooting and Maintenance

3.1 TROUBLESHOOTING
The axle should be checked, serviced and repaired only
This section provides an easy reference guide covering by experienced service technicians who are aware of all
the most common problems that may occur during safety instructions and particular component features.
operation.
Note: Contact your Local Caterpillar Dealer if internal
axle repair is required during the warranty period.

Problems Possible Causes

1 2 3 4 5 6 7 8 9 10 11

Wheel vibration; front tire resistance; • • • • •

halfshaft breakage.

Steering is difficult; vehicle goes • • • • •

straight while turning.

No differential action; jamming while • • • • •

steering.

Extreme loud noise from the • • • • • • • •

transmission.

Uneven wear of tire. • • • • • • • •

Friction noise. • • • • • • •

Vibration during forward drive, • • • • •

intermittent noise.

1. Incorrect installation/defective axle - Correct 6. Blocked differential - Abnormal functioning of the

installation or repair or replace the differential in differential or breakage/blockage of command
case it does not survive one of the test phases. device. Verify assembly and all components.
2. Overloading/incorrect weight distribution - Vehicles with wide steering angle may proceed with
Remove excessive weight and redistribute load, kicks, have steering difficulty or cause pneumatic
following instructions related to the vehicle. wearing at sharp turns. Reduce the steering angle to
minimum and decelerate when the vehicle begins to
3. Different rotation radius of the tires - If one tire kick.
has a smaller radius, it will cause partial wheel
slipping when force is applied. The other tire with 7. Incorrect wheel adjustment - Verify group integrity
bigger radius will have to support all the work. and wheel side bearings. Adjusting accordingly.
Replace the tire or adjust pressure to have same 8. Spoiled or worn out axle parts - Check the
radius on both tires. condition of ring gear, pinion gear, bearings etc.
4. Broken halfshaft - It is not advisable to operate the Replace when ever necessary.
vehicle with a broken halfshaft. It is acceptable to 9. Contamination in the axle box or incorrect
move the vehicle (engine off, unloaded) a few assembly parts - Look for foreign particles. Check
meters away only. assembly of the various parts of the axle.
5. Bent halfshaft - Replace halfshaft.

31200455 3-1
Troubleshooting and Maintenance

10. Incorrect adjustment of bevel gear set: Parts of 11. Incorrect use of the product - Refer to the
the transmission worn out - Replace or adjust as Operation and Maintenance Manual for proper use.
required.

Problem Cause Action

Ring gear tooth broken on the 1. Excessive gear load compared Replace bevel gear set. Follow care-
outer side. to the one foreseen. fully the recommended operations
2. Incorrect gear adjustment for the adjustment of bevel gear set
(excessive backlash). backlash.

3. Pinion nut loose.

Ring gear tooth broken on the 1. Load bump Replace bevel gear set. Follow care-
inner side. 2. Incorrect gear adjustment fully the recommended operations
(insufficient backlash). for the adjustment of bevel gear set
backlash.
3. Pinion nut loose.

Pinion or ring gear teeth worn. 1. Insufficient lubrication Replace bevel gear set. Follow care-
2. Contaminated oil. fully the recommended operations
for the adjustment of bevel gear set
3. Incorrect lubrication or depleted backlash. Use correct lubricants, fill
additives. up to the right levels and replace
4. Worn out pinion bearings that according to the recommended inter-
cause an incorrect pinion axle- vals.
backlash and wrong contact
between pinion and ring.

Overheated ring and pinion teeth. 1. Prolonged functioning at high Replace bevel gear set. Use proper
See if gear teeth have faded. temperatures. lubrication, fill up to the right level
2. Incorrect lubrication. and replace at recommended inter-
vals.
3. Low oil level.
4. Contaminated oil.

Pinion teeth pitting. 1. Excessive use. Replace bevel gear set. Use proper
2. Insufficient lubrication. lubrication, fill up to the right level
and replace at recommended inter-
vals.

Axle beam body bent 1. Vehicle overloaded. Replace axle beam body.
2. Vehicle accident.
3. Load bump.

Worn out or pitted bearings. 1. Insufficient lubrication. Replace bearings. Use proper lubri-
2. Contaminated oil. cation, fill up to the right level and
replace at recommended intervals.
3. Excessive use.
4. Normal wear out.
5. Pinion nut loose.

3-2 31200455
 Troubleshooting and Maintenance

Problem Cause Action

Oil leakage from gaskets and 1. Prolonged functioning at high Replace the gasket or seal and
seals. temperature of the oil. matching surface if damaged. Use
2. Oil gasket assembled incor- proper lubrication and replace at rec-
rectly. ommended intervals.

3. Seal lip damaged.

4. Contaminated oil.

Excessive wearing out of input 1. Exhaustive use. Replace the flange. Check that the
flange spline. 2. Pinion nut loose. pinion spline is not excessively worn
out. Replace bevel gear set if
3. Pinion axle backlash. required.

Fatigue failure of pinion teeth. See 1. Exhaustive use. Replace bevel gear set.
if the fracture line is well defined 2. Continuous overload.
(wave lines, beach lines).

Pinion and ring teeth breakage. 1. Crash load of differential com- Check and/or replace other differen-
ponents. tial components.

Side gear spline worn out. Replace 1. Excessive use. Replace differential gear group.
all scratched washers (excessive Replace halfshaft if required.
backlash).

Thrust washer surface worn out or 1. Insufficient lubrication. Use proper lubrication and fill up to
scratched. 2. Incorrect lubrication. the right level. Replace at recom-
mended intervals. Replace all
3. Contaminated oil. scratched washers and those with
0,1 mm thickness lower than the new
ones.

Inner diameter of tapered roller 1. Excessive use. Replace bearing. Check pinion axial
bearing worn out. 2. Excessive pinion and axial backlash. Use proper lubrication, fill
backlash. up to the right level and replace at
recommended intervals.
3. Insufficient lubrication.
4. Contaminated oil.

Bent or broken halfshaft. 1. Vehicle intensively operated or Replace

overloaded.

Halfshaft broken at wheel side. 1. Wheel support loose. Replace. Check that wheel support
2. Beam body bent. is not worn out or wrongly adjusted.

31200455 3-3
Troubleshooting and Maintenance

Problem Cause Action

Noise while driving. 1. Excessive backlash between 1. Adjust

pinion and ring gear.
2. Worn out pinion and gear ring. 2. Replace
3. Worn out pinion bearings. 3. Replace
4. Pinion bearings loose. 4. Adjust
5. Excessive axial pinion backlash 5. Adjust
6. Worn out differential bearings. 6. Replace
7. Differential bearing loose. 7. Adjust
8. Ring gear out of roundness. 8. Replace
9. Low lubricant level. 9. Oil level
10. Poor or wrong lubricant. 10. Replace
11. Bent halfshaft. 11. Replace

Noise while driving in neutral. 1. Noise coming from axles is usu- 1. Replace or adjust (see above)
ally heard when vehicle moves in
neutral gear but are not loud.
2.Incorrect backlash between pin-
ion and ring (sound heard while 2. Replace
decelerating disappears while
increasing speed).
3. Pinion or input flange worn out. 3. Adjust

Intermittent noise. 1. Ring gear damaged. 1.Replace bevel gear set

2. Differential box bolts loose. 2. Tighten to proper torque

Constant noise. 1. Ring gear teeth or pinion dam- 1. Replace bevel gear set.
aged.
2. Worn out bearings. 2. Replace
3. Pinion spline worn out. 3. Replace
4. Bent halfshaft. 4. Replace

Noise while steering. 1. Worn out differential gears. 1. Replace

2. Worn out differential box or spi- 2. Replace
der.
3. Differential thrust washers worn 3. Replace
out.
4. Half shaft spline worn out.
4. Replace

3-4 31200455
 Troubleshooting and Maintenance

3.2 OIL CHANGE AND SERVICE CHECKS

31200455 3-5
Troubleshooting and Maintenance

Note: To drain and fill the oil and check the oil level, the 4. Unscrew the oil fill plug (1) and fill to the bottom of
axle must be horizontal. the level plug hole with the specified oil. Wait to
allow the oil to flow through the axle. Check oil level
Danger: There is a risk of violent oil ejection, carefully and fill to the specified level if necessary. Screw the
follow all the safety procedures provided in this manual plug (1) to the prescribed torque. See “Tightening
and the Operation and maintenance manual provided Torques and Sealants” on page 2.12.
with the machine.
1. Clean the breather (3) and the surrounding area.

5. Before draining the oil from wheel end, rotate the

2. To drain the oil, remove the level plug (1) and the wheel end so that the plug (4) is at the highest
drain plug (2). position (pos.A) and partially unscrew to release
3. Drain all oil.Clean the plug (2) and tighten it to the possible pressure. Rotate the wheel end so that the
prescribed torque. See “Tightening Torques and plug (4) is toward the ground (pos.B). Remove the
Sealants” on page 2.12. plug and drain the oil.

3-6 31200455
 Troubleshooting and Maintenance

6. Rotate the wheel end so the hole (4) is in the

position shown in the graphic above. Fill to the
bottom, of the fill plug hole with specified oil. See
“Technical Features” on page 2.5. Tighten plug to
the prescribed torque. See “Tightening Torques and
Sealants” on page 2.12.

31200455 3-7
Troubleshooting and Maintenance

3.3 SERVICE SCHEDULE

Specified maintenance intervals are for standard-duty
use. Severe operating conditions may require shorter
intervals.
Note: Maintenance intervals shown in the table below.

This operation must be performed only by personnel authorized by the Caterpillar dealer.
This operation must be performed only by trained personnel.
(1) Which of both conditions comes first.
(2) 50 hours for severe operating condition.
(3) At the season end if you have not reached the indicated work hours.

3.3.1 Lubricants Application Range

3-8 31200455
 Troubleshooting and Maintenance

3.4 GREASE IN ASSEMBLY

31200455 3-9
Troubleshooting and Maintenance

This Page Intentionally Left Blank

3-10 31200455
 Section 4
Disassembly/Assembly/Adjustment

4.1 STEERING CYLINDER

4.1.1 General Drawing

4.1.2 Disassembly Note: Some of the graphics in the Disassembly/

Assembly/Adjustment section of this manual may
not show your axle; however, indicated procedures
are correct and may be utilized.

Note: If necessary use a hammer.

Important: Do not damage the threaded pin ends.
During the assembly replace the nuts (2 and 15).
1. Disconnect the steering sensor connector (16).
Remove the nuts (2 and 15) then extract the tie rods
(4 and 13) from the swivel housing (3 and 14).

31200455 4-1
Disassembly/Assembly/Adjustment

4.1.3 Assembly

2. Remove the tie rods (4) and (13) from the cylinder
rods by loosening the nuts (5), then checking their
conditions. Unscrew the ball joints (6) and (11). 1. Assemble new seals and O-Rings (19) on the
Remove the fastening bolts (7) and (10). Extract the cylinder heads (1) and (17), on the piston (20) and
bushing (8) using an extractor with a M18 screw. the cylinder body (18). Insert the rod (20) into the
cylinder (18) then assemble the cylinder heads (1)
and (17).

3. Remove the cylinder (9) from the axle.

Danger: Wear safety gloves.

2. Assemble the steering cylinder (9) to the axle. Cool
the bushing (8) to a temperature lower than -100°C
with liquid nitrogen. Assemble the bushing (8) with a
punch and hammer.

4. Detach the cylinder heads (1 and 17) from the

cylinder case (18) and remove it from the rod (20).
Remove the rod (20) from the cylinder case (18).
Remove all the seals and O-Rings (19) from the
cylinder head (1 and 17) and piston (20).

4-2 31200455
 Disassembly/Assembly/Adjustment

Note: It’s important to unscrew the nut (5) to carry out

this operation. Repeat the mentioned operations on the
other side.
5. Align the swivel housing (3) with the axle. Screw the
tie rod (4) so that its ball joint can be inserted into the
swivel housing (3) arm.

3. Apply the specified sealant on the thread (Sec. 2.8)

and tighten the fastening screws (10) and (7) to the
prescribed torque (Sec. 2.8). Screw the ball joints (6)
and (11) to the ends of the rod (20) to the requested
torque (Sec. 2.8).
6. Insert the ball joint of the tie rod (13) into its housing
on the swivel housing (14).
Assemble and tighten the lock nut (15) to the
requested torque (Sec. 2.8).
Assemble the cotter pin (16).
Repeat the mentioned operations at the other side of
the swivel housing.
Note: Screw the nuts (5) and (12) of the tie rods (4) and
(13) only when the toe-in adjustment has been carried
out. See: Section 4.13.

4. Assemble the nuts(5) and (12) then the tie rods (4)
and (13) to the ball joints (6) and (11).

7. Screw the nuts (5 and 12) of the tie rods (4 and 13)
only when the toe-in adjustment has been
completed.
See: Section 4.13

31200455 4-3
Disassembly/Assembly/Adjustment

4.2 EPICYCLIC REDUCTION GEAR

GROUP

4.2.1 General Drawing

4.2.2 Disassembly 1. Unscrew the plug (1) and drain the oil completely
from the epicyclic reduction gear.
See: section 3.2.

4-4 31200455
 Disassembly/Assembly/Adjustment

4. If required, replace the planetary gears (8) as

follows:
- remove the fastening bolts from every pin;
- remove the washer;
- remove the planetary gears from the pins;
- collect the needle bearings and washer;
- collect the thrust washer.

4.2.3 Assembly

2. Unscrew and remove the two fastening bolts (3) of

the planetary carrier (2) with a wrench.

1. Position the planetary carrier (2) on a workbench.

Insert the thrust washer (5) on every pin.

3. Remove the planetary carrier (2) from the wheel hub

(14) and collect the relative O-Ring (13). Position the
planetary carrier (2) on a workbench and check its
wear conditions.

2. Position the planetary carrier (2) on a workbench.

Note: grease the needle bearings well (see section
3.4).Insert the needle bearings in the planetary
gears. Fit the planetary gears to the planetary carrier
pins. Insert the thrust washer and the snap rings to
the planetary carrier pins.

31200455 4-5
Disassembly/Assembly/Adjustment

3. Fit the thrust washer (10) to the pins (4). Assemble

the fastening bolts (11) and tighten to the prescribed 5. Fit the epicyclic reduction gear group to the wheel
torque (Sec. 2.8). hub (13). Assemble the fastening screws (3) and
tighten them to the prescribed torque (Sec. 2.8).
Note: The pin on thrust washers (7) must be fitted into
the hole of the pins (4).

6. Top up the oil on the wheel hub (See: Sec.3.2). Fit

4. Assemble a new lubricated O-ring (13) on the wheel the oil plug (2) on the planetary carrier (1) and
hub (14). tighten to the prescribed torque (Sec. 2.8).

4-6 31200455
 Disassembly/Assembly/Adjustment

4.3 WHEEL HUB GROUP

4.3.1 General Drawing

4.3.2 Disassembly

Note: Remove the epicyclic reduction gear group before

disassembling wheel hub group.

Important: Do not damage the double U-Joint while

completing the following procedure.
1. Insert a lever between the swivel housing (14) and
the axle beam and fit it into the double U-Joint.
With the lever, push the double U-Joint in the
direction of the wheel hub to allow lock ring (1)
removal.

31200455 4-7
Disassembly/Assembly/Adjustment

4. To extract the wheel carrier, screw two of the just

removed bolts (5) in the threaded holes.
Remove the wheel carrier (7) with the epicyclic ring
gear (4).

2. Remove the lock ring (1) from the double U-Joint

shaft. Collect the double U-Joint shaft washers (2)
and (3).

5. Remove the steel lock ring (8) and the wheel carrier
(7) from the epicyclic ring gear (4).
Only if necessary, remove the centering bushes (6)
from the wheel carrier with a hammer and the
special tool (Sec. 5).

3. Unscrew and remove the fastening bolts (5) from the

wheel carrier (7).

6. Remove the wheel hub (11) using levers and a

hammer to facilitate the operation.
Note: Collect the bearing cone (9).

4-8 31200455
 Disassembly/Assembly/Adjustment

Note: The following is a destructive operation for the 9. Remove the swivel housing (14) from the axle beam
seal ring (13). and from the short shaft of the double U-Joint.
Collect the belleville washers (26) and (27).
7. Position the wheel hub (11) on a flat surface and
remove the seal ring (13).
Remove the bearing cones (9 and 12) using a
hammer and a suitable drift.
Remove the bearing cone (12) from the swivel
housing end (14) using a suitable extractor.

10. Position the swivel housing (14) on a flat surface and

take the seal ring (25) out with an extractor.
Note: This is a destructive operation for the seal ring.
Turn the swivel housing and take the bush (24) out,
8. Unscrew and remove the fastening screws (15) and using a suitable drift and hammer.
(21) from the upper (17) and lower (19) king pins.
Danger: before removing the king pins (17) and
(19), secure the swivel housing (14) with a belt or a
rope to a hoist or any other supporting device,
observe all current safety regulations to guarantee
operator’s safety.
Remove the king pins (17) and (19).

31200455 4-9
Disassembly/Assembly/Adjustment

4.3.3 Assembly

3. If the cone (18) of the spherical joint has been

1. If it has been previously removed, reassemble the previously removed, reassemble it to the lower king
steering stop composed by the spacer (29), the pin (19) using the special tool (Sec. 5) under a press.
screw (23) and the nut (22). Carefully grease the king pin (17) and (19) housings
Note: do not tighten the nut (22) until the steering with specific grease. See: section 3.4.
angle adjustment has been completed. Position the belleville washers (26) and (27) on the
See: section 4.13. king pin (17) and (19) housings.

2. Force the bush (24) into the swivel housing (14) with
Important: secure the swivel housing (14) with a belt or
the special tool (Sec. 5) and a hammer or a press.
a rope to a hoist or any other supporting device.
Assemble the seal ring (25) on the swivel housing
(14) with the special tool (Sec. 5) and a hammer. 4. Protect the splined end of the axle shaft by winding it
Carefully grease the seal ring (25). with an adhesive tape to avoid damage to the seal
See: section 3.4. ring (25).
Assemble the swivel housing (14) on the axle beam
and after assembly, remove the adhesive tape
completely.

4-10 31200455
 Disassembly/Assembly/Adjustment

5. Assemble the king pins, the lower (19) and the upper 7. Force both bearing cups (9 and 12) to their wheel
(17), and tighten the retaining screws (21) and (16) hub (11) housings using the special tool (Sec. 5)
to the requested torque (Sec. 2.8). under a press or with a hammer. Insert the seal ring
(13) into the wheel hub (11) with the special tool
Note: Make sure that the belleville washers (26) and (Sec. 5) and a hammer.
(27) are in the correct position.
Note: Do not lubricate the seal ring (13).

6. The special operation "Set Right" of the bearings (9 8. Assemble the bearing cone (12) on the swivel
and 12) does not require preload or backlash housing (14) end. Assemble the wheel hub (11) on
adjustment. However, before assembling new the swivel housing (14) and fit the bearing cone (9).
components check the indicated dimensions.

A = 27.590 ÷ 27.640 mm
B = 81.775 ÷ 81.825 mm
C = 27.000 ÷ 27.100 mm

31200455 4-11
Disassembly/Assembly/Adjustment

11. Assemble the wheel carrier group on the wheel hub

9. Position the wheel carrier (7) on a workbench and using the two projecting bushes as dowel pins and
force the bushes (6) to the carrier surface level with screw the relative screws (5) in order to attach the
the special tool (Sec. 5). At least two bushes ring bevel gear with the wheel hub.
(diametrically-opposed) should be set slightly higher
that the carrier surface level to be used as dowel
pins.

12. Force all the hub dowel bushes (6) completely with
the special tool (Sec. 5) and a hammer.
10. Preassemble the wheel carrier (7) and the epicyclic Assemble the wheel carrier (7) fastening bolts (5)
ring gear (4) with the special locking ring (8) shown and tighten to the requested torque (Sec. 2.8).
in the illustration above.

4-12 31200455
 Disassembly/Assembly/Adjustment

13. Insert a lever between the swivel housing (14) and

the axle beam and fit it into the double U-Joint. With
the lever, push the double U-Joint in the direction of
the wheel hub to make the lock ring (1) insertion
easier.

14. Slide the thrust washers (3) and (2) onto the double
U-Joint shaft end (24).
Insert the lock ring (1) at the end of the splined hub
and push it into its housing.
Note: Check that the lock ring (1) is correctly fitted in its
seat. Push the double U-Joint thoroughly.

31200455 4-13
Disassembly/Assembly/Adjustment

4.4 PARKING BRAKE GROUP

4.4.1 General Drawing

4.4.2 Disassembly

Important: proceed with care to avoid damage to the

brake pads (14).
1. Loosen the two nuts (13). 2. Unscrew the two screws (11).

4-14 31200455
 Disassembly/Assembly/Adjustment

5. Unscrew and remove the fastening screws (6) from

the brake caliper support (7).Remove the brake
caliper support (7) from the central body.

3. Remove the brake caliper (12).

6. Remove the seal (3) from the central housing (9)

with a puller.
Remove the snap ring (16) and the bearing (15) from
the central housing (9).
Note: This is a destructive operation for the seal.

4.4.3 Assembly

4. Remove the snap ring (1) and the input flange (2).
Note: Collect the O-ring (4) and the spacer (5)

1. Insert the bearing (15) into the central body using

the special tool (Sec. 5). Insert the snap ring (16).
Insert a new seal (3) into the central body using the
special tool (Sec. 5).
Note: Lubricate the seal lip (3) (see 3.4).

31200455 4-15
Disassembly/Assembly/Adjustment

2. Insert the dowel pin (10) and the brake caliper Important: proceed with care to avoid damaging the
support (7) on the central body (9). brake pads (14).
Tighten the fastening screws (6) to the specified 4. Position the brake caliper (12) on the flange disc (2).
torque (see 2.8).

Important: after tightening nuts, make sure that a 1

± 0.5 mm space is left between the nuts (13) and the
3. Grease the O-Ring (4) (see 3.4). spacers shown in the graphic above.
Insert the washer (5) on the splined pinion end, a 5. Screw in the bolts (11) and tighten the nuts (13) to
new O-Ring (4), the input flange (2) and the lock ring the specified torque (see 2.8).
(1).

4-16 31200455
 Disassembly/Assembly/Adjustment

4.4.4 Parking Brake Caliper

Some of the following graphics may not show your axle,

but indicated procedures are correct.

6. Note in the illustration above that the brake caliper of

the 314-8934 axle is positioned downward.

1. The parking brake assembly is a ball and cam,

sliding caliper brake designed for use primarily as
a parking brake, with some service brake capability.
The brake (shown in the photos above and the
exploded graphic on the following page) has an
open caliper design to facilitate changing linings,
along with a retraction spring to reduce drag from
the brake pads and the disc.
Note: The brake assembly should not be subject to high
pressure wash.

31200455 4-17
Disassembly/Assembly/Adjustment

2. PARTS

b.
Tighten inner Adjustment Nut (12) until firm
3. MOUNTING PROCEDURE
... contact is made with the disc by the linings.
a. insert mounting bolts through sleeves (9) and Torque to 13-14 Nm (115-125 lb. in). Make
thread brake mounting locking nuts as far as certain lever is in proper operating position for
possible on mounting bolts. application.
This is not required if brake assembly comes c. Back of inner Adjustment nut (12) 4 to 6 flats (1/
with the sleeve/bolt sub-assy (9). Position the 2 ÷1 turn) and check that disc is free to move.
brake over disc align with mounting holes in
d. Tighten outer Locking Nut (13) against inner
mounting bracket. Adjustment Nut (12) to lock Adjustment Bolt (2)
b. Thread mounting bolts (9) into mounting bracket, in place. Torque to 61÷74Nm (45÷55 lb. ft).
adjusting bolts until a 0,5 ÷ 1,5 mm exists
between the Sleeves and Locking Nuts. Tighten 5. BALL AND CAM REPLACEMENT
the Locking Nuts to 115 Nm of torque against the
a. Remove both Adjustment Locking Nuts (12 and
bracket.
13), Thrust, stainless steel and Hardened
c. Refer to Adjustment Procedure to set backlash of Washer (11, 16, 17), Lever (1), and Boot (3) from
installed brake assembly. Adjustment Bolt (2).
b. Remove outer cam (4) and Ball Assembly (8)
4. ADJUSTMENT PROCEDURE from Adjustment Bolt (2).
a. Loosen two Adjustment Locking Nuts (12 and c. Use a screwdriver, or similar tool, to gently pry
13). inner Cam (4) protrusions on back of cam, loose
from Torque Plate (5), and remove the
Adjustment Bolt (2). Remove seal (15) from
Adjustment Bolt (2).

4-18 31200455
 Disassembly/Assembly/Adjustment

d. Install new Seal (15) on Adjusting Bolt (2), 7. SLEEVE SEAL REPLACEMENT
inserting through inner Cam (4) until Seal (15) L

bottoms out on Torque plate. a. Loosen the two locking nuts on the mounting
bolts and remove the mounting bolt/sleeve
Note: Prior to installation of the cams (4), it is assembly (9) from the brake.
recommended to apply anti-seize and lubricating
b. Insert sleeve seals (18) between the torque
compound to ramp areas of cams.
plates (5 and 7) and align with the sleeve bores.

e. Install new Cam (4) on Adjustment Bolt (2), Note: Prior to installation of the mounting bolt
taking care to orient protrusions into Holes in and sleeve assembly, it is recommended that
Torque Plates (5) grease (anti-seize and lubricating compound) be
f. Install Ball Assembly (8) onto Adjusting Bolt (2), applied to the sleeve and bores of the torque
orienting balls into pockets of Inner Cam (4). plates.
Install outer Cam (4) onto Adjustment Bolt (2)
orienting pockets onto Balls of Ball Assembly (8). c. Insert mounting bolt and sleeve assembly
Install boot (3) over cam assembly. through the front torque plate (5) and sleeve seal
g. Install lever (1), using protrusions on back of (18), and back torque plate (7).
outer Cam (4) and holes in Lever (1) to orient d. Mount per paragraph 3b and adjust per
lever to proper operating position. paragraph 4.
h. Install remaining washer and nuts and follow
procedure in Paragraph 5.
8. BRACKET CABLE RETENTION REPLACEMENT
Note: Make sure to orient coated face of thrust a. Remove the screws (19) of the bracket (20) from
washer (11) toward stainless steel washer (17). the front torque plate (5). Remove the bracket
(20).
6. LINING REPLACEMENT b. Position the bracket (20) in correspondence with
the threaded holes of the pad support of the
a. Loosen two adjustment Locking Nuts (12 and 13) torque plate(5).
enough to remove each Torque Plate (5 and 7) c. Fix the bracket (20) to the front torque plate (5)
away from disc far enough to provide backlash to with the appropriate screws (19).
remove old carrier and lining assemblies and Tighten the screws to 63 Nm.
install new ones. (It may be necessary to remove
one or both nuts).
b. Collapse the two Lining retraction Springs (10)
and remove them from brake Head Assembly.
c. Remove Torque Plates (5 and 7) away from disc,
move Carrier and Lining Assemblies (6) out of
pockets, and remove from the Brake Head
Assembly from the side.

Note: Prior to installation of the new linings, it is

recommended that a coating of anti-seize and
lubricating compound be applied to the interface
of the sleeve (9) and the torque plates (5 and 7).

After grease has been applied, move torque

plates back and forth on sleeve as far as
possible to insure that the grease has been
introduced into the bores of the torque plates.
d. Install new Carrier and Lining Assemblies (6) in
each Torque Plate (5 and 7).
e. Install the two Lining Retention springs (10) into
Brake Head Assembly. Be sure spring’s feet are
positioned properly in holes in both Lining Carrier
Assemblies (6). Adjust brake per Paragraph 3.

31200455 4-19
Disassembly/Assembly/Adjustment

4.5 FLANGE GROUP

4.5.1 General Drawing

4.5.2 Disassembly

2. Remove seal ring (3), spacer (5), O-rings (4) and (6)
and the washer (7).
1. Remove lock ring (1) and flange (2).
Note: The preceding is a destructive operation for the
seal rings.

4-20 31200455
 Disassembly/Assembly/Adjustment

4.5.3 Assembly

1. Attach the washer (7) and a new O-ring (6) to the

pinion end. Put the new O-ring (4) on the spacer (5).
Attach the new seal ring (3) to the differential
support with the special tool (Sec. 5) and hammer.

2. Assemble the flange (2).

Attach the lock ring (1) to the pinion end.

31200455 4-21
Disassembly/Assembly/Adjustment

4.6 TRUNNIONS GROUP

4.6.1 General Drawing

4.6.2 Disassembly

1. Remove the front (3) and rear support (14). 2. If necessary, remove the bushings (7) and (11) and
the thrust washers (8) and (10) using a punch.
Note: This procedure is a destructive operation for the
components.

4-22 31200455
 Disassembly/Assembly/Adjustment

4.6.3 Assembly

3. Remove the fastening bolt (13).

Remove the bushing (12) from the rear support.
1. Position the front and rear supports on a work bench
and assemble their respective thrust bushings (6)
and (2).
Insert the lock screws (2) and (13) and tighten them
to the specified torque (see 2.8).
Insert a new O-ring (5) in the thrust bushing of the
rear support.

4. Loosen the lock screw (2) with the grease nipple and
remove the bushing (6) from the support.
If necessary, replace the O-Ring (5).

Note: Apply sealant (ref. sec. 2.8) to the contact

surfaces before replacing bushings.
2. If necessary, replace and insert the bushings (4) and
(15) using a drive and hammer.

31200455 4-23
Disassembly/Assembly/Adjustment

3. Insert the washers (8) and (10).

Heat the bushings (7) and (11) at 110-120°C for
about four minutes, then attach to the axle housing
(9).
Note: If necessary, assemble bush (7)and (11) with a
pad and a hammer.

4. Insert the rear and front supports on the axle beam.

Important: Do not damage the O-ring during this
process!

4-24 31200455
 Disassembly/Assembly/Adjustment

4.7 BRAKE GROUP

4.7.1 General Drawing

4.7.2 Disassembly

2. Remove the brake counter plates (6) and (9), brake

1. Remove the beam trumpet assembly from the brake plates (7) and (10), and the brake disk carrier gear
flange (1). Refer to Section 4.8, Axle Beam Group, (8) from the brake flange (1).
disassembly.
Note: Remember the position of the brake disk carrier
gear (8), it must be reassembled in the same position.

31200455 4-25
Disassembly/Assembly/Adjustment

4.7.3 Assembly
Note: Assemble the differential support group (see
section 4.9) before assembling the brake group.

3. Remove the self-adjust kit’s (5) screw and collect all

the components.
Remove the positive brake piston (4).

1. Collect the brake piston (4).

With the special tool (Sec. 5) and a hammer, push
the bushings into the self-adjust housing until they
are aligned with the piston supporting inner surface.

4. Remove the O-Rings (2) and (3) from the brake

piston (4).

2. The bushings must be aligned with the piston

supporting inner surface.

4-26 31200455
 Disassembly/Assembly/Adjustment

3. Assemble new O-Rings (2) and (3) to the brake 6. Assemble the self-adjust kit (5) and tighten the
piston (4). Lubricate the O-rings. screws to the prescribed torque (see 2.8).

4. Insert the piston (4) into the brake cylinder (1) and Note: Assembly of the self-adjust kit (5).
position the special tool (Sec. 5) on the piston.
Note: Position the positive brake piston (4) with a slot 7. Check that the brake plate (7) and (10) and the
aligned with the hydraulic connection or with the brake drive plate (6) and (9) (see graphic at top of
inspection hole on the brake cylinder (1). next page) do not show any sign of burning. If they
do, replace them.
5. With a lever anchored to an eyebolt, apply just Furthermore, check brake plate wear and if
enough pressure to insert the piston into the brake necessary, replace it.
flange.
Note: See the following section 4.7.4, Brake disks
replacement.

31200455 4-27
Disassembly/Assembly/Adjustment

Important: Place the brake disk carrier (8) as shown in

the next graphic. Assemble brake disks with holes
aligned.

9. This is the correct position of the step on the external

diameter of the brake disk carrier (8).

Important: The brake piston must be pushed in the

original position if worn brakes are replaced by new disks.
Note: See the following section 4.7.4, Brake disks
replacement,

10. Assemble the beam trumpet group to the brake

flange (1).
See: section 4.8, Axle Beam Group

8. Reassemble all the components of the brake group

as shown in the graphic above: brake counter plate
(6), brake plate (7), brake disk carrier (8), brake
counter plate (9) and brake plate (10).

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 Disassembly/Assembly/Adjustment

4.7.4 Brake Disk Replacement

3. To replace worn brake disks with new disks the

1. Remove the beam trumpet group from the brake brake piston must be pushed in the original position.
flange (1). Remove straight threads, bleeds or plugs from the
See: section 4.8.2, disassembly service brake oil port.
Danger: risk of ejection of oil from the axle.

2. Remove from the brake flange (1) the brake counter

plate (9) and brake plate (10), the brake disk carrier
4. Push the brake piston (4) at the end of stroke using
gear (8) the brake plate (7) and the brake counter
the special tool (Sec. 5) and the handle (Sec. 5) with
plate (6).
a hammer.
Note: Remember the position of the brake disk carrier, it
Note: Position the pad with accuracy to avoid damage
must be reassembled in the same position.
to the brake piston.

31200455 4-29
Disassembly/Assembly/Adjustment

5. Reassemble all the components of the brake group 7. Assemble the beam trumpet group to the brake
as shown in the graphic above: brake counter plate flange (1).
(6), brake plate (7), brake disk carrier (8), brake See: section 4.8.3, assembly
counter plate (9) and brake plate (10).
Important: Place the brake carrier (8) as shown in the
next graphic.

6. This is the correct position of the step on the external

diameter of the brake disk carrier.

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 Disassembly/Assembly/Adjustment

4.8 AXLE BEAM GROUP

4.8.1 General Drawing

4.8.2 Disassembly
See: previous sections before disassembling this group.

1. Put alignment marks on the central body, brake 2. Remove double U-Joint (9) from axle beam trumpet
cylinders and beam trumpets in order to identify the (3).
parts on right side and left side.

31200455 4-31
Disassembly/Assembly/Adjustment

Important: Position the axle on supports fitted to hold 6. Remove the bushing (7) only if the wear conditions
either the central body or the beam trumpets, following require this.
their separation or secure every group to a lifting device
with ropes or belts.
3. Unscrew and remove the fastening bolts.

7. Remove the upper king pin bushing (5) and the ball
bearing cup (6) from the king pin seats using a
suitable extractor only if the wear conditions require
4. Remove the axle beam trumpet (3). this.
Remove the O-Ring (2).

Important: Be careful not to damage the housing for the

bushing during the following procedure. See graphic at
top of next column to identify parts.

5. Remove the seal rings (8) from the axle beam (3)
with an extractor.
Note: The preceding is a destructive operation for the
seal rings.

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 Disassembly/Assembly/Adjustment

4.8.3 Assembly

3. Assemble the seal ring (8) with the special tool (Sec.
5) and a hammer.
Important: Wear safety gloves.
1. Cool the upper king pin bushing (5) and the ball
Important: Assemble the seal ring (8) as shown in
bearing cup (6) at a temperature lower than -100°C
graphic above.
with liquid nitrogen.
Assemble the bushing (5) on the upper king pin seat Note: Carefully grease the seal rings (see section 3.4).
with the special tool (Sec. 5) and a hammer.
Assemble the ball bearing cup (6) on the lower king
pin seat with the special tool (Sec. 5) and a hammer.

4. Lubricate the new O-Ring (2).

Assemble the new O-Ring on the axle beam trumpet
(3).
2. Insert the bushing (7) into the axle beam (3) with the
special tool (Sec. 5) and a hammer.

31200455 4-33
Disassembly/Assembly/Adjustment

5. Insert the double U-Joint (9) inside the axle beam

trumpet (3). 7. Assemble the fastening bolts (4).
Tighten fastening bolts (4) to the requested torque
Important: Do not damage the seal ring (8).
(see 2.8) according to the sequence shown in step
8.

Important: Support the groups properly as already

pointed out for disassembly.Do not damage the O-Ring 8. Tighten fastening bolts (4) according to sequence
(2) during the procedure. shown in graphic.
6. Assemble the beam trumpet (3) to the central body
(1) on the correct side following the reference marks
applied prior to disassembly.

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 Disassembly/Assembly/Adjustment

4.9 DIFFERENTIAL SUPPORT GROUP

4.9.1 General Drawing

4.9.2 Disassembly

2. Secure the brake cylinder (6) to a hoist with ropes or

safety belts. Remove the fastening screw (7).

1. Measure the starting total preloading T0 of the

bearings (pinion-crown gear system), using a
dynamometer whose cord is wound on the pinion
splined end. Note the value T0 that is necessary in
the bearings reassembly.

31200455 4-35
Disassembly/Assembly/Adjustment

6. Remove the O-Ring (2) from the central body (1).

3. Remove the brake cylinder.

Important: Ensure the differential box is free.
4. Remove the O-Ring (5) from the brake cylinder (6).

7. Loosen and remove screw (10) and ring nut retainer

(9) from brake cylinder (6).

5. Remove the differential housing (3).

8. Unscrew and remove the adjuster ring nut (8) from

the brake cylinder (6) with the special tool (Sec.5).

4-36 31200455
 Disassembly/Assembly/Adjustment

2. Lubricate and assemble new O-Ring (2) on every

9. Use a driver and a hammer to remove the bearing side of the central body (1).
cup (4) from the brake cylinder (6).
Important: Do not invert the bearing cups if the bearings
are not replaced

4.9.3 Assembly

3. Position the brake cylinder (6) on a flat surface and

force the bearing cup (4) using the special tool (Sec.
5).
Important: Do not invert bearing cups if the bearings are
not replaced.

1. Assemble the pinion group before assembling the

differential support group.
See: section 4.12.3, assembly

31200455 4-37
Disassembly/Assembly/Adjustment

4. Measure the external diameter C of the bevel crown 7. Assemble the fastening screw (7) at the position
assembled to the differential housing. shown in the graphic above. Tighten the fastening
Calculate the value: screw to the requested torque (see 2.8).
R=C/2 mm Assemble in the shown position an axle beam
trumpet fastening screw M16x2x160 (part #4 in
Note: This value is necessary to measure the backlash section 4.8) to a torque of 80 Nm on both sides with
between the pinion and crown. suitable shim.
.

5. Assemble a new well lubricated O-Ring (5) on the

brake cylinder (6) housing. 8. Fastening screws M16x2x160 (part #4 in 4.8) with
First assemble the left brake cylinder (Lh) to the suitable shim. Tighten bolt to the torque of 80 Nm
central body (1). Insert the differential group into the (on both sides).
central body (1).
Important: The bevel gear must be placed on the right
side (Rh).
6. Assemble the right brake cylinder (Rh).
Note: Check that the reference marks made prior to
disassembly between the brake cylinders and the central
body coincide.

4-38 31200455
 Disassembly/Assembly/Adjustment

11. Move the bracket of the special tool (Sec. 5)

installed on the differential housing hole alternately
by hand.
9. Screw both adjuster ring nuts (8) using the special Measure backlash between pinion and crown.
tool (Sec. 5) till the backlash is eliminated and the Check if the backlash is within the prescribed range:
differential bearings are slightly loaded. 0.15÷0.30 mm
Set the backlash by turning the adjusting ring nuts
(8) using the special tool (Sec. 5).

10. Assemble the special tool (Sec. 5) on the differential

housing hole. Position a comparator with the feeler
in contact with and at a 90° with respect to the
surface of the special tool bracket, in
correspondence with the reference R value. 12. Adjust the ring nuts (8), remembering that:
- if the measured backlash is less than the given
tolerance range, screw the ring nut from the side
opposite to the ring gear and unscrew the opposite
one of the same measure (A);
- if the measured backlash is greater than the
given tolerance range, screw the ring nut from the
side of the ring gear and unscrew the opposite one
of the same measure (B).

31200455 4-39
Disassembly/Assembly/Adjustment

13. Once the adjustment of the pinion-bevel gear Important: All the preloads should be measured without
backlash had been carried out, check to ensure the seal rings.
there is minimum preloading on the differential 15. If the bearings have been replaced, measure the
housing bearings. total preloading T of the bearings with a
Repeat the whole sequence of the above mentioned dynamometer whose cord is wound on the special
operations till the indicated conditions are reached. tool (Sec. 5) inserted on the end of the pinion shaft.

16. The total preloading Tm is measured on the special

14. Once the pinion-ring gear backlash has been
established, measure the total preloading Tm of the tool (Sec. 5) (gauge diameter Dm = 104.4 mm).
bearings (pinion-crown bevel gear system), using a The measured value should be within the following
dynamometer whose cord is wound on the pinion range:
splined end. Tm = (Pm+7.9) ÷ (Pm+11.9) N (314 - 8936)
Tm = (Pm+7.9) ÷ (Pm+11.29) N (314 - 8937)
Note: Do not use this method with new bearings, if the Where Pm is the effective preloading measured on
bearings have been replaced see next step.
the special tool (Sec. 5) (gauge diameter Dm
The measured value should be the starting value (see
section 4.9): = 104.4 mm). See: section 4.12, assembly

Tm = T0
Important: all the preloads should be measured without
the seal rings.

4-40 31200455
 Disassembly/Assembly/Adjustment

19. If the measurement is not within the requested

range, check the assembly of each component and
17. Once the pinion-ring gear backlash has been operate on the adjuster ring nuts (8) of the
established, measure the total rolling torque (TT) of differential support:
- if the total preloading is less than the given
the bearings (pinion-crown bevel gear system) with
range, screw in both adjuster ring nuts by the same
a torque meter and the special tool (Sec. 5).
measure, keeping the pinion-ring gear backlash
See: section 2.8
value unchanged (A);
Important: All the preloads must be measured without - if the total preloading is greater than the given
the seal installed. range, unscrew both adjuster ring nuts by the same
measure, keeping the pinion-ring gear backlash
value unchanged (B)

18. The total rolling torque TT must be within the

following range (see C.4):
TT= (TP+0.41)÷(TP+0.62) Nm where TP is the pinion
20. Once all the adjustment operations are completed,
bearing preloading. fit the adjuster ring nut retainers (9) and their
Note: See procedure described in 4.12. respective screws (10), tightening them to their
requested torque (see 2.8).
Important: Turn the adjuster ring nuts (8) slightly in order
to allow the assembly.
21. Remove the M16x2x160 fastening screws on both
sides.
See step 8 of this assembly procedure.

31200455 4-41
Disassembly/Assembly/Adjustment

4.9.4 Bevel gear marking test.

3. Movements to correct excessive contact on the tooth

1. To test the marks of the bevel gear teeth, paint the tip and at the tooth base.
ring gear with red lead paint.
The marking test should always be carried out on 1) move the pinion away from the bevel gear for type
the ring bevel gear teeth and on both sides. X contact adjustment.

2) Move the pinion toward the bevel gear for type Z

contact adjustment.

2. OK Correct contact:
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.

Z Excessive contact on tooth tip:

Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash (see step 3)

X Excessive contact at the tooth base:

Move the pinion away from the ring bevel gear and
then move the ring bevel gear to the pinion in order
to adjust the backlash (see step 3).

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 Disassembly/Assembly/Adjustment

4.10 DIFFERENTIAL GROUP LIMITED

SLIP

4.10.1 General Drawing

4.10.2 Disassembly

See: section 4.9 before disassembling the differential

group./ Important: this procedure will free both differential half
boxes (4) and (12), take care not to drop the internal
components.

1. Lock the differential with a clamp.

Unscrew the fastening screws (1) and remove the
bevel crown gear (2).

31200455 4-43
Disassembly/Assembly/Adjustment

4.10.3 Assembly

Note: Mark the two half boxes before separating them

in order to reassemble them in the same position as they 4. Assemble the bearing cones (3) and (13) on the half
were before disassembly. housings (4) and (12), using the special tool (Sec. 5)
2. Disassemble the differential box in two half boxes (4) and a hammer.
and (12) complete with relative components.
Disassemble the components.
Check the operating and wear condition of the
components.

Note: The first disk (7) must be assembled with friction

material on the disk’s side and the flat surface of the sun
gear (8) side.
5. Position a half housing (4) or (12) on a workbench
and assemble all inner components: locking
3. Remove the bearing cones (3) and (13) from the half
differential counterdisks (6), locking differential disks
boxes (4) and (12), using two levers or a three-hold
(5) and (7), sun gears (8), spider gears (10), and
extractor.
thrust washers (11) as shown in the general drawing
at the beginning of this section. See: Differential
disks specifications in section 2.7.3.
Join the two half boxes, aligning the reference marks
that were made on them prior to disassembly.

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 Disassembly/Assembly/Adjustment

6. Before matching surfaces, make sure they are

perfectly clean. Degrease and clean them with
appropriate detergents.
Position the bevel crown gear (2) on the half box
(14).
Note: Check the dowel pin (4) position.
7. Apply the specified sealant on the thread (see 2.8)
and tighten the bolts (1) to the requested torque (see
2.8).

31200455 4-45
Disassembly/Assembly/Adjustment

4.11 DIFFERENTIAL GROUP - OPEN

4.11.1 General Drawing

4.11.2 Disassembly

Important: The following will free both differential half

boxes (4) and (12). Take care not to drop the internal
components.
1. Lock the differential with a clamp.
Unscrew the fastening bolts (1) and remove the
bevel gear crown (2).

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 Disassembly/Assembly/Adjustment

4.11.3 Assembly

2. Make alignment marks on the two half boxes before

splitting them.
Disassemble the differential box into two half boxes
(4) and (12) complete with relative components.
1. Assemble the bearing cones (3) and (13) on the half
Disassemble all the components.
housings (4) and (12) using the special tool (Sec. 5)
Check the operating and wear condition of the
and a hammer.
components.

3. Remove the bearing cones (3) and (13) of the half

2. Position a half housing (4) or (12) on a workbench
boxes (4) and (12) using two levers or a three-hold
and assemble all inner components: thrust washers
extractor.
(5) and (11), sun gears (6) and (10), spider gears (8),
and thrust washers as shown in the graphic above.
3. Join the two half boxes, aligning the reference marks
made prior to disassembly.

31200455 4-47
Disassembly/Assembly/Adjustment

4. Position the bevel crown gear (2) on the half box (4).
Note: clean the matching surfaces carefully.
Apply the specified sealant on the thread (see 2.8)
and tighten the screws (1) to the requested torque
(see 2.8).

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 Disassembly/Assembly/Adjustment

4.12 PINION GROUP

4.12.1 General Drawing

4.12.2 Disassembly
1. Remove the differential group (See section 4.9.2,
disassembly).
Measure the starting preloading P0 of the pinion
bearings using a dynamometer whose cord is wound
on the pinion splined end.
Note that the value P0 is necessary during the
bearings reassembly.
See section 4.9.3, assembly.

31200455 4-49
Disassembly/Assembly/Adjustment

2. Unscrew the locking ring nut (10) using the special

tools (Sec. 5). 4. Once the bevel pinion (1) has been removed, collect
Note: This operation will damage the locking ring nut; the washer (6), the collapsible spacer (5) and the
the nut (10) must be replaced when assembling the washer (4).
group. Note: The collapsible spacer (5) must be replaced when
assembling the group.

3. Tap the end shaft with a soft hammer to remove the

bevel pinion (1).
5. Check the bearing cups wear condition.
Collect the washer (9) and the bearing (8).
If bearing replacement is necessary, remove bearing
cups from central body with a drift punch and
hammer.

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 Disassembly/Assembly/Adjustment

4.12.3 Assembly

6. Remove the bearing cone (3) from the bevel pinion

(1) with a standard bearing extractor. 1. Place the central body (6) on a workbench.
Collect the shim (2). Fit the bearing cups into their seats using the special
tools kit (Sec. 5).

7. Check all pinion components for wear.

Remember, the locking ring nut (10) and the 2. Use the special tools false pinion (Sec. 5). and false
collapsible spacer (5) must be replaced when differential box (Sec. 5) to measure the conic
reassembling the unit. distance.
Insert the bearing cones and false pinion into the
seats.
Tighten the locking ring nut (10) to eliminate the
backlash.

31200455 4-51
Disassembly/Assembly/Adjustment

3. Check the correct position of the right and left brake 5. To adjust bevel gear/pinion measure the distance
cylinder and differential housing supports, using the "A" with a depth gauge.
reference marks placed on them and on the central Calculate the value "X" as follows:
body (6). X=(A+C)-B mm
Assemble the two brake cylinders with their
fastening bolts. where "B" and "C" are known.

6. "From the value "X" deduct the value "V" (stamped

4. Insert the false differential box (Sec. 5) into the on the pinion head) to get the value "S".
central body (6). Make sure the false differential box
is inserted in both differential support housings. S=X-V mm
.

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 Disassembly/Assembly/Adjustment

7. Choose the shim (2) with thickness value (S) in mm 9. Insert the chosen shim (2) with the chamfer against
and the number needed from among the following the gear on the pinion shaft (1).
available shims range: Force the bearing (3) on the pinion shaft (1) with the
special tool (Sec. 5) under a press, making sure that
2.5 - 2.6 - 2.7 - 2.8 - 2.9 - 3.0 - 3.1 - 3.2 - 3.3 - 3.4 it is well set.
Assemble the shim (4), a new collapsible spacer (5)
and the shim (6) to the pinion shaft.
Note: Always use a new collapsible spacer (5).

8. Loosen and remove the locking ring nut (10).

Remove the false pinion (Sec. 5) and the bearing
cones from the central body (7).
Disassemble the false differential box (Sec. 5) from
the brake cylinders, then unscrew the screws to 10. Insert the bevel pinion (1) unit into the central body
remove the brake cylinders. (7) and the bearing (8) into the pinion shaft, as
shown in the graphic above.
Force the bearing (8) in position with the special tool
(Sec. 5) and a hammer.
Note: Push the pinion against the central body to
perform this operation.

31200455 4-53
Disassembly/Assembly/Adjustment

13. To measure the preloading PM of the pinion taper

11. Insert the ring nut washer (9) and screw a new
roller bearings (3) and (8), use a dynamometer
locking ring nut (10) on the pinion end.
whose cord is wound on the end of the pinion shaft
Screw the locking ring nut (10) in, using the special
(1).
tools (Sec. 5).
Important: The torque setting is given by the preloading Note: Do not use this method with new bearings, if the
measurement on bearings (3) and (8); tighten the locking bearings have been replaced, see next step.
ring nut (10) gradually. The measured value must be the starting value (see
4.12.2)
Note: If the tightening is excessive, the collapsible
spacer (5) will be damaged and must be replaced and PM = PO
the procedure repeated. See: step 17 of this procedure.
12. When you check the preloading, it is advisable to
slightly beat both pinion ends (1) with a soft hammer
to help set the bearings (3) and (8).
Important: All preloadings must be measured without the
seal rings.

14. If the pinion taper roller bearings (3) and (8) are new,
measure the preloading P of the bearings. Use a
dynamometer whose cord is wound on the special
tool (Sec. 5) inserted on the end of the pinion shaft.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed the
specified torque value.

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 Disassembly/Assembly/Adjustment

15. The effectively preloaded PM is measured on the 16. The measured value TP must be within the following
special tool (Sec. 5) (gauge diameter DM = 104.4 range:
mm). TP= 1.6÷2.4 Nm
The measured value should be within the following
range:
PM= 30.6÷45.8 N

Important: The measured value is for new bearings.

17. Once the requested preloading is achieved, stake

the locking ring nut (10) using a hammer and chisel.

Note: In addition to using steps 14 and 15 to measure

preloading of the bearings, the pinion shaft bearings
rolling torque TP may also be measured with a torque
meter and the special tool (Sec. 5).
Important: Remember that all the preloads must be
measured without the seal ring.

31200455 4-55
Disassembly/Assembly/Adjustment

18. Assemble the differential.

See: section 4.9.3.

19. Assemble the flange group.

See: section 4.5.3.

4-56 31200455
 Disassembly/Assembly/Adjustment

4.13 TOE-IN/STEERING ANGLE

4.13.1 General Drawing

4.13.2 Toe-in adjustment

1. Put two equal one-meter-long linear bars on the

wheel sides and lock them with two nuts on the
wheel hub stud bolt.
Important: The two bars must be fixed on their middle so
they are perpendicular to the supporting surface and
parallel to the pinion shaft axis; align the two bars.

31200455 4-57
Disassembly/Assembly/Adjustment

external diameter of the wheel hubs flange,

therefore the measured value (M) at the bars ends
must be related to the ratio between length of the bar
and flange diameter.
nominal toe-in (sec. 2.6) = A±1 ---> measured toe-in =
M±3

2. Measure the distance M (measured value) in mm

between the bars end with a tapeline.
Note: Keep the minimum value, swinging the
measurement point.

4. 314-8936
Check that the difference of the measurements
between the wheel hubs diameter ends is within the
requested tolerance range.
See: "Toe-in" in Sec. 2.6.
The nominal toe-in value (A) is referred to the
external diameter of the wheel hubs flange,
therefore the measured value (M) at the bars ends
must be related to the ratio between length of the bar
and flange diameter.
nominal toe-in (sec. 2.6) = A0-2 ---> measured toe-in =
M0-5

3. 314-8937
Check that the difference of the measurements
between the wheel hubs diameter ends is within the
requested tolerance range.
See: "Toe-in" in Sec. 2.6.
The nominal toe-in value (A) is referred to the

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 Disassembly/Assembly/Adjustment

4.13.3 Steering angle adjustment

5. If toe-in is incorrect, use two wrenches on the guide

rods (1) to screw the two joint tie rods (3) in and out
1. Use the same bars that were attached for the toe-in
equally until the toe-in is within the specified
adjustment and a long bar perfectly leaned over the
tolerance (see 2.8).
machined part of the central body (pinion side), so
the two bars form an acute angle at the maximum
steering.

6. After adjusting the toe-in, screw in the lock nuts (2)

of the guide rods (1) to the specified tightening
torque (see 2.8).
2. Set a protractor to the specified angle (Sec. 2.6) and
position it on the long bar.
Move a wheel side until it forms, with the two bars,
the angle fixed by the protractor.

31200455 4-59
Disassembly/Assembly/Adjustment

3. Adjust the mechanical steering stop by screwing the 4. Steer completely towards the other side and repeat
stop bolt (4) in or out, locking it with the locknut (5) to the same adjustments for the mechanical steering
the specified tightening torque (see 2.8). stop that were done in step 3.

Important: Check the position of the stops on the

Important: Check the position of the stops on the opposite side, both screws must touch the steering pads
opposite side, both screws must touch the steering stop at the same time.
pads at the same time.

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 Disassembly/Assembly/Adjustment

4.14 TESTING AFTER ASSEMBLY

4.14.1 Testing methods

1. With the engine off, lift the axle so the tires are off of
the ground.

2. Engage the gear so the pinion becomes locked.

3. With the help of another person standing on the

opposite side, begin testing the assembly by rotating
both wheels forward as much as possible. (Both
wheels should be blocked after a while.)

4. Keeping the pinion locked, free the right wheel and

rotate the left wheel in the line of march. Rotate the
right wheels in the opposite direction.
The wheel (left one) will move freely without difficulty
and the right wheel will move in the opposite
direction if the assembly has been carried out
correctly.

5. Repeat the same test procedure in the opposite

direction (reverse gear).

Note: IF ONE WHEEL DOES NOT ROTATE FREELY

IN BOTH DIRECTIONS, check all assembly procedures
step-by-step.

Check to ensure the brakes are adjusted correctly and

functioning properly.

31200455 4-61
Disassembly/Assembly/Adjustment

This Page Intentionally Left Blank

4-62 31200455
 Section 5
Special Tools

5.1 TOOL USAGE

The special drift/pad used to assemble the seals,
bearings, and bushings should always be used with the
interchangeable handle, and the safety handle in order to
protect the hands.

31200455 5-1
Special Tools

5-2 31200455
 Special Tools

31200455 5-3
Special Tools

5-4 31200455
31200455