4472.751.101 Repair Instructions AV-110 & AV-133

REPAIR INSTRUCTIONS
AV 133
Bus axle with compact bearing
BUSES
Copyright © ZF Friedrichshafen AG
This document is protected by copyright.

Complete or partial reproduction or distribution of this document is not
permitted without the approval of ZF Friedrichshafen AG.
Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Table of Contents
1 Preface ....................................................................................................................... 5
1.1 Document overview .......................................................................................................................... 5
2 Safety Instructions ...................................................................................................... 6

2.1 General safety instructions .............................................................................................................. 6
2.2 Signal words and symbols .............................................................................................................. 9
3 Notes on Repairs and Assembly ................................................................................. 10

3.1 General notes ...................................................................................................................................... 10
3.2 Cleaning the ZF product .................................................................................................................. 10
3.3 Dismantling the ZF product ............................................................................................................ 10
3.4 Assembling the ZF product ............................................................................................................ 10
3.5 Cleaning parts .................................................................................................................................... 11
3.6 Reusing parts ...................................................................................................................................... 11
3.7 Replacing parts .................................................................................................................................. 11
3.8 Reworking parts ................................................................................................................................. 12
4 Technical Data ............................................................................................................ 13

4.1 Oil grade .............................................................................................................................................. 13
4.2 Type plate ............................................................................................................................................. 13
5 Setting Data ............................................................................................................... 14
6 Tightening Torques ..................................................................................................... 15
7 Workshop Equipment ................................................................................................. 17

7.1 Special tools ........................................................................................................................................ 17
7.2 Standard tools and fixtures ............................................................................................................. 30
7.3 Operating supplies and auxiliary materials ................................................................................. 35
8 Dismantling ................................................................................................................ 36
8.1 Clamp the axle ................................................................................................................................... 36
8.2 Drain oil ................................................................................................................................................ 36
8.3 Remove mounting parts ................................................................................................................... 38
8.4 Removal of brake ............................................................................................................................... 39
8.5 Remove and dismantle hub. ........................................................................................................... 42
8.5.1 Remove hub ........................................................................................................................................ 42
8.5.2 Dismantling hub ................................................................................................................................. 44
8.6 Remove tachometer .......................................................................................................................... 47
8.7 Remove and dismantle left portal drive ....................................................................................... 48
8.7.1 Remove left portal drive ................................................................................................................... 48
8.7.2 Dismantling left portal drive ........................................................................................................... 48
8.8 Remove breather ................................................................................................................................ 57
8.9 Remove and dismantle right portal drive. ................................................................................... 58
8.9.1 Remove right portal drive ................................................................................................................ 58
8.9.2 Dismantle right portal drive ............................................................................................................ 58
EN 4472.751.001 - 2015-11 3
Table of Contents
8.10 Dismantle differential. ...................................................................................................................... 68

8.11 Remove input ...................................................................................................................................... 70
9 Assembly .................................................................................................................... 74
9.1 Install input .......................................................................................................................................... 74
9.2 Assemble differential ........................................................................................................................ 79
9.3 Setting backlash and differential bearing rolling torque and checking axial run-out and
contact pattern. .................................................................................................................................. 81
9.4 Install shaft seal onto the drive ...................................................................................................... 86
9.5 Assemble and install left portal drive ........................................................................................... 88
9.5.1 Assemble left portal drive ............................................................................................................... 88
9.5.2 Install left portal drive ....................................................................................................................... 102
9.6 Assemble and install right portal drive ........................................................................................ 103
9.6.1 Assemble right portal drive ............................................................................................................. 103
9.6.2 Install right portal drive .................................................................................................................... 116
9.7 Install breather neck ......................................................................................................................... 117
9.8 Install breather .................................................................................................................................... 118
9.9 Install tachometer .............................................................................................................................. 118
9.10 Assemble and install hub ................................................................................................................ 120
9.10.1 Assembling hub ................................................................................................................................. 120
9.10.2 Install hub ............................................................................................................................................ 124
9.11 Install brake ......................................................................................................................................... 127
9.12 Install mounting parts ....................................................................................................................... 129
9.13 Filling oil ............................................................................................................................................... 131
10 Testing, Measuring, Adjusting ..................................................................................... 133

10.1 Check contact pattern ...................................................................................................................... 133
10.1.1 Contact pattern on crown wheel shifted towards the root ..................................................... 134
10.1.2 Contact pattern on the crown wheel shifted towards the tip ................................................ 135
11 Annex ......................................................................................................................... 136

11.1 Overview of revisions ........................................................................................................................ 136
4 EN 4472.751.001 - 2015-11
Preface
1 Preface
This documentation was developed for specialized staff trained in the operation of ZF products by
ZF Friedrichshafen AG (hereinafter referred to as "ZF").
Object of documentation is a ZF product. State of design acc. to date of issue.
The figures serve to illustrate the operation or the workflow and may deviate from your ZF product.
Illustrations and figures are not drawn to scale; therefore, no conclusions about size and weight can be
drawn.
The work described below may be performed by authorized, trained, and instructed specialized staff only.
It is the responsibility of the company that performs repair, assembly, or maintenance tasks to ensure that
their specialized staff is properly trained and that current documents are made available.
ZF Friedrichshafen AG
1.1 Document overview
The specifications listed in these documents must be observed because they are a prerequisite for fault-
free operation of the product and for the warranty granted by ZF Friedrichshafen AG. Please speak with
your contact if you need binding documents.
Document no. Designation Technical information

4472.758.101 Operating Instructions AV 110/AV 133
Tab. 1
EN 4472.751.001 - 2015-11 5
Safety Instructions
2 Safety Instructions
2.1 General safety instructions
Please read all safety instructions. Failure to comply with safety information and instructions may lead to
property damage, serious injuries, or death.
Intended use
The ZF product is exclusively intended for the application as defined in the contract and as agreed on
delivery. Any other or extended form of use does not comply with this definition of intended use. The
intended use includes compliance with this documentation and other applicable documents, in order to
avoid malfunctions and damage in operation.
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate.
However, this ZF product may pose dangers if improperly used by unauthorized, untrained, and
uninstructed specialized staff or if not used according to its intended use.
Repair, assembly, maintenance, and commissioning

Perform repair, assembly, and maintenance work exclusively according to this documentation on hand and
other applicable documents paying particular attention to the points mentioned below:
▪ Work must be performed in a professional manner and according to the technical provisions.
▪ Work must only be performed by trained, instructed, and authorized specialized staff.
▪ Only original ZF spare parts may be used.
▪ Only original ZF accessories may be used.
▪ Only original ZF special tools may be used.
▪ Changes and modifications of the ZF product may lead to the expiry of the operator's license, warranty,
or guarantee.
In case of damage, immediate action is mandatory in order to restore or guarantee full functionality and
safety / operational safety of the ZF product and to minimize the extent of damage.
In case of damage, contact ZF Services and have the following information ready:
▪ Product type, product parts list number, and serial number
▪ Total mileage [km]
▪ Progress of the damage
▪ Damage pattern
To avoid personal injury and damage to third-party products and the ZF product, this safety information,
all valid safety regulations, and legal requirements must be observed.
Country-specific safety, accident prevention, and environmental regulations apply irrespective of the
information provided in this document.
Safety-relevant workwear must be worn for all work. Depending on the type of work, additional protective
equipment, e.g. protective goggles, protective gloves, hard hat, and apron must be used. The workwear
must fit tightly so that it cannot get caught in turning or protruding parts.
6 EN 4472.751.001 - 2015-11
Safety Instructions
After completion of repair, assembly, and maintenance work, as well as inspections, the specialized staff
must ensure that the ZF product is once more functioning perfectly and is safe to operate.
The user/operator is responsible for assigning the corresponding section of the documentation to the
correct target group. The former must ensure that the corresponding section of the documentation is kept
in close proximity to the ZF product and remains accessible to the concerned target group.
Using ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the ZF
product's operational safety.
Unless explicitly permitted, no repair, assembly, and maintenance work may be performed while the
engine is running. Secure the engine against an unintentional start and the vehicle against unintentional
movements. Attach a "Do not operate" sign which is visible for everyone! Keep uninvolved parties away.
Prior to starting work, always secure the ZF product properly using suitable means. Do not work on ZF
products that are only held with lifting equipment or a crane. Risk of injury from tilting or falling parts
and/or tools.
▪ Do not walk under suspended loads.
▪ Keep distance.
Lifting and moving heavy parts without tools may lead to health damage or serious injury.
▪ Only use permitted means of transport, lifting tools with a sufficient load capacity, and suitable lifting
technology.
▪ Observe safety regulations.
Increased risk of injury in the event of contact with cooled down or heated parts. Only touch parts when
wearing suitable protective gloves.
Noise
Wear suitable ear protection at all workplaces with a sound pressure level above 85 dB(A). The country-
specific safety regulations and the accident prevention regulations apply irrespective of this. Noise can
lead to a higher risk of accidents if the noise affects the perception of acoustic signals, warning calls, or
other sounds alerting to danger.
Handling operating supplies and auxiliary materials

Increased risk of injury at contact with heated, cooled down, or caustic operating supplies and auxiliary
materials (e.g. lubricants, cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources – do not smoke.
Store operating supplies and auxiliary materials in suitable and correctly labeled containers.
Use suitable protective clothing, protective gloves, and protective goggles/face protection.
Pay attention to the manufacturer's regulations and accident prevention regulations.
EN 4472.751.001 - 2015-11 7
Safety Instructions
Immediately seek medical assistance after contact with heated, cooled down, or caustic operating
supplies and auxiliary materials.
Environment
Operating supplies and auxiliary materials may not be allowed to enter the soil, groundwater, or sewage
system.
▪ Request material safety data sheets for the corresponding ZF products from your responsible
environmental protection authority, and observe them.
▪ Collect operating supplies and auxiliary materials in a sufficiently large container.
▪ Dispose of operating supplies and auxiliary materials, waste, containers, soaked cleaning cloths,
contaminated filters, etc. in accordance with the regulations of the environmental protection laws.
▪ Pay attention to the manufacturer's regulations and accident prevention regulations.
When selecting operating supplies and auxiliary materials, pay attention to health risks, environmental
compatibility, disposal regulations, and your country-specific opportunities to dispose of such materials
properly.
8 EN 4472.751.001 - 2015-11
Safety Instructions
2.2 Signal words and symbols
This document contains particularly highlighted safety instructions which start with one of the following
signal words depending on the severity of the danger.
DANGER
The signal word DANGER indicates a dangerous situation that, if not prevented, will lead to a severe
injury or death.
ð Information as to how the danger can be prevented.
WARNING
The signal word WARNING indicates a dangerous situation that, if not prevented, can lead to a severe
injury or death.
CAUTION
The signal word CAUTION indicates a dangerous situation that, if not prevented, can lead to a slight or
moderate injury.
The signal word NOTICE indicates a situation that, if not prevented, can lead to property damage.
ð Information as to how the property damage can be prevented.
The following symbols are additionally used:
This symbol refers to additional, safety-relevant information.
This symbol indicates information concerning special workflows, methods, application of aids, etc.
EN 4472.751.001 - 2015-11 9
Notes on Repairs and Assembly
3 Notes on Repairs and Assembly
3.1 General notes
▪ Please read this documentation prior to starting repair or assembly work.

▪ Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF
product is available. ZF Service Information may contain tests or supplements to the product or to
repair processes, which may not be included in this documentation. ZF Service Information is available
from all ZF Services Partner or from the ZF-ServiceLine.
▪ In cases of doubt, always contact the relevant expert departments of ZF Services.
▪ Please ensure that all work on the ZF product is performed expertly and under clean conditions.
▪ Use the specified special tools and equipment intended for the working procedures described.
▪ Please perform all work according to the working procedure described.
▪ Cover opened ZF products to prevent entry of foreign matter.
▪ Cover parts that have been removed and that are reusable, and protect them against dirt and damage.
▪ After completion of work and inspections, specialized staff must ensure that the ZF product is again
functioning perfectly and is safe to operate.
3.2 Cleaning the ZF product
Clean the ZF product with an appropriate cleaning agent prior to repair or assembly works.
Possible damage to ZF product due to water infiltration.

ð Be careful when using a pressure washer on the ZF product.
3.3 Dismantling the ZF product
▪ To avoid mixing up parts, the parts must be clearly assigned to the disassembled ZF product. In
particular, this applies to gear parts, reusable spacer washers or shims, electronic components, etc.
▪ Assemblies which must not be disassembled or are only available as spare parts assembly are
described accordingly. Please refer to the spare parts catalog for the ZF product.
▪ Inspect the parts during disassembly in order to find a potential cause of damage.
3.4 Assembling the ZF product
Assemble the ZF product at a clean workplace. The order of work steps, configuration data, and
tightening torques must be retained. Use the special tools specified in the work steps.
Bearings
The provisions for assembly of the bearings are described in the respective work step. Each bearing
integrated must be lubricated with operating oil after assembly.
10 EN 4472.751.001 - 2015-11
Sealing compound
Sealing compound is only to be used when described as such in the work step (refer to section Operating
supplies and auxiliary materials). Please observe the manufacturer guidelines and processing instructions.
Apply the sealing compound thinly and evenly. Keep oil ducts and oil bores free of sealing compound.
When assembling the parts, no sealing compound must enter the oil ducts or oil bores.
Retaining agents
Retaining agents are only to be used when described as such in the work step (refer to section Operating
supplies and auxiliary materials). Please observe the manufacturer guidelines and processing instructions.
Oil
Fill the ZF product with oil before operation. For the procedure and approved oil grades, refer to the
document valid for the ZF product, the type plate, and/or the latest List of Lubricants TE-ML. These
documents are available at all ZF Services Partner and here www.zf.com.
3.5 Cleaning parts
▪ Clean all reusable parts.

▪ Remove sealing compound residue on sealing faces or retaining agent residue, e.g. in tapped holes or
on splines.
▪ Clean joining surfaces.
▪ Clean blind holes and blind hole threads.
▪ Lubricating bores, oil bores, oil ducts, bores for oil press fits, and lubricating grooves must be free from
dirt, preservative, and foreign matter. Check for free passage.
▪ Hose assemblies, tubes, and joining elements must be free from dirt, oil, and damage. Clean dirty or
oily parts. Check for free passage. Replace damaged parts.
▪ Clean all cavities and reliefs.
▪ Remove preservative from new parts.
3.6 Reusing parts
Authorized, specialized staff assess whether parts can be reused. Replace parts
▪ if they are damaged
▪ if they are worn, e. g. bearings, multidisks, thrust washers, etc.
▪ if they have a permanent deformation
▪ if they have been overheated during operation or during disassembly.
Only replace with original ZF parts or ZF-approved parts. Please refer to the spare parts catalog for the ZF
product.
3.7 Replacing parts
The following parts must always be replaced:

▪ Bolts with reduced shank and seals
▪ Single-use parts
EN 4472.751.001 - 2015-11 11
▪ Sealing rings
▪ Safety plates
▪ Shaft sealing rings
Only replace with original ZF parts or ZF-approved parts. Please refer to the spare parts catalog for the ZF
product.
3.8 Reworking parts
Authorized, specialized staff assess whether parts need to be reworked.
Minor damage on reusable components can be removed and reworked with suitable special tools if the
component's function is not impaired.
Minor damage includes:

▪ Indentation marks on sealing faces
▪ Score marks or burs caused by the disassembly of the ZF product
▪ Frictional corrosion
▪ Damage caused by paint or corrosion
If rework is needed on spacer washers or shims because of clearance settings, ensure that the reworked
surface is level with the starting face and has the same surface quality.
Debur all edges that can cause chip formation during the assembly process or represent a risk of injury for
the fitter. Remove burs or other similar rough surfaces.
12 EN 4472.751.001 - 2015-11
Technical Data
4 Technical Data
4.1 Oil grade
Damage to ZF product due to incorrect oil possible.

ð Only use oils listed in the valid ZF List of Lubricants.
Observe the information on the type plate.
Oils approved and listed in the ZF List of Lubricants TE-ML 12 are binding.
The latest ZF List of Lubricants can be obtained from all ZF Service Centers and viewed at www.zf.com.
4.2 Type plate
The type plate contains the most important data.
1 Product designation
ZF Friedrichshafen AG 2 Serial number
Made in Germany 3 Parts list number
4 Transmission ratio
Type Serial-No.
1 2
5 Oil specification
Parts List No. Total Ratio / Version
6 Approximate oil quantity for initial filling
3 4
7 No. of List of Lubricants
ltr. List of lubricants
8 Customer spec. number, if known to ZF
Oil
5 6 TE-ML 7
TE-ML The following data should be quoted when making inquiries
TE-ML or undertaking repairs: 1, 2, 3
Customer´s 8
Code No.
40_020020_01
Fig. 1 Type plate
EN 4472.751.001 - 2015-11 13
Setting Data
5 Setting Data
Designation Dimensions Measuring Comment

instrument Chapter/section
pinion bearing rolling torque 4 Nm – 10 Nm Torque wrench ▪ Install input, page 74
with dial gauge
Backlash bevel gear set e. g. 0.22 mm (±0.0 Dial gauge For ideal value see Reassemble
4 mm) differential
▪ Setting backlash and differential

bearing rolling torque and checking
axial run-out and contact pattern.,
page 81
Axial run-out crown wheel max. 0.08 mm Dial gauge ▪ Setting backlash and differential
page 81
Differential bearing rolling 4 Nm – 7 Nm ▪ Setting backlash and differential
torque bearing rolling torque and checking
page 81
Total rolling torque at axle ratio Total rolling torque = Torque wrench ▪ Setting backlash and differential
i < 7.38 Pinion bearing rollin with dial gauge bearing rolling torque and checking
g torque + 2 Nm (±1 axial run-out and contact pattern.,
Nm) page 81
Total rolling torque at axle ratio Total rolling torque = Torque wrench ▪ Setting backlash and differential
i > 7.38 Pinion bearing rollin with dial gauge bearing rolling torque and checking
g torque + 1.5 Nm ( axial run-out and contact pattern.,
±0.5 Nm) page 81
Pinion bearing rolling torque 4.5 Nm – 10.5 Nm Torque wrench (with shaft seal)
with dial gauge
▪ Install shaft seal onto the drive,
page 86
setting of the intermediate 0.01 mm preload– Dial gauge ▪ Assemble left portal drive, page 88
gear bearing 0.05 mm clearance ▪ Assemble right portal drive, page 103
Output gear bearing 0.03 mm preload– ▪ Assemble left portal drive, page 88
0.03 mm clearance ▪ Assemble right portal drive, page 103
14 EN 4472.751.001 - 2015-11
Tightening Torques
6 Tightening Torques
Designation Tightening torque Measuring Comment

Emergency loosening screw 20 Nm +5 Nm Torque wrench ▪ Removal of brake, page 39
(maximum loosening
torque)
Cylindrical screw M10 - 10.9 68 Nm Torque wrench ▪ Dismantling left portal drive, page 48
Double hexagon nut 1,000 Nm Torque wrench ▪ Install input, page 74
M50 x 1.5 and torque ▪ Install shaft seal onto the drive,
multiplier page 86
Locking screw M14 x 1.5 - 250 Nm Torque wrench ▪ Assemble differential, page 79
12.9
Cylindrical screws M14 - 10.9 185 Nm Torque wrench ▪ Setting backlash and differential
page 81
Torx screw M14 x 1.5 - 10.9 185 Nm Torque wrench ▪ Setting backlash and differential
page 81
▪ Assemble left portal drive, page 88
▪ Install left portal drive, page 102
▪ Assemble right portal drive, page 103
▪ Install right portal drive, page 116
▪ Install breather, page 118
Stud bolt 33 Nm Torque wrench ▪ Assemble left portal drive, page 88
Cylindrical screw 185 Nm Torque wrench ▪ Assemble left portal drive, page 88
▪ Assemble right portal drive, page 103
Hexagon nut 200 Nm Torque wrench ▪ Install left portal drive, page 102
Torx screw M16 x 1.5 - 10.9 270 Nm Torque wrench ▪ Assembling hub, page 120
Slotted nut M105 x 1.5 100 Nm Torque wrench ▪ Install hub, page 124
Torx screw M18 x 1.5 - 10.9 440 Nm Torque wrench ▪ Install hub, page 124
Fit bolt M16 x 1.5 - 10.9 270 Nm Torque wrench ▪ Install brake, page 127
Hexagon screw M16 x 1.5 - 270 Nm Torque wrench ▪ Install brake, page 127
10.9
Locknut M16 x 1.5 - 10.9 195 Nm (±15 Nm) Torque wrench ▪ Install brake, page 127
Emergency loosening screw 20 Nm (+5 Nm) Torque wrench ▪ Install brake, page 127
Hexagon screw M20 x 1,5 - 620 Nm Torque wrench ▪ Install mounting parts, page 129
10.9
Hexagon screw M18 x 1.5 - 90 Nm Torque wrench ▪ Install mounting parts, page 129
8.8
Hexagon nut 70 Nm Torque wrench ▪ Install mounting parts, page 129
Hexagon screw M18 x 1,5 - 390 Nm Torque wrench ▪ Install mounting parts, page 129
10.9
Screw plug oil drain M36 x 1.5 130 Nm Torque wrench ▪ Filling oil, page 131
EN 4472.751.001 - 2015-11 15
Tightening Torques
Designation Tightening torque Measuring Comment

Screw plug oil filling 70 Nm Torque wrench ▪ Filling oil, page 131
M24 x 1.5
Screw plug oil level M24 x 1.5 70 Nm Torque wrench ▪ Filling oil, page 131
16 EN 4472.751.001 - 2015-11
Workshop Equipment
7 Workshop Equipment
7.1 Special tools
The required quantity is listed. Please inquire as to packaging unit before ordering.
Figure Order no. Quantit Comment

Designation y
Chapter/section
5870.350.093 1
Fixture
▪ Clamp the axle, page 36
5870.350.000 1
Assembly truck
▪ Clamp the axle, page 36

▪ Dismantling left portal drive,
page 48
▪ Dismantle right portal drive,
page 58
▪ Assemble left portal drive,
page 88
▪ Assemble right portal drive,
page 103
5870.281.046 1
Load carrying fixture
▪ Removal of brake, page 39

▪ Install brake, page 127
5870.204.084 1 M16
Eyebolt
▪ Removal of brake, page 39

▪ Install brake, page 127
EN 4472.751.001 - 2015-11 17
Workshop Equipment

Designation y
Chapter/section
5870.345.036 1 1 set = 2 units
Pry bar
▪ Remove hub, page 42

▪ Dismantling hub, page 44
5870.401.146 1
Slotted nut wrench

▪ Install hub, page 124
AA01.395.095 1
Load carrying fixture

5870.100.069 1
Assembly fixture
▪ Dismantling hub, page 44
18 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
AA00.844.345 2 M20 x 1.5
Load ring
▪ Remove left portal drive, page 48

▪ Remove right portal drive,
page 58
page 81
▪ Install left portal drive, page 102
▪ Install right portal drive, page 116
5870.350.110 1
Connection plate

page 48
page 58
page 88
page 103
AA02.041.051 1
Driver tool

page 48
page 88
page 103
AA01.311.408 1
Rapid grip

page 48
EN 4472.751.001 - 2015-11 19
Workshop Equipment

Designation y
Chapter/section
5873.002.001 1 Use only in connection
with gripping device.
Basic tool
M95 x 2, length of sleeve
▪ Dismantling left portal drive, 125 mm
page 48
page 58
▪ Dismantle differential., page 68
▪ Remove input, page 70
AA02.049.488 1
Disassembly device

page 48
5870.281.054 1 M105 x 1.5
Eye nut

page 48
page 58
page 88
page 103
5870.300.009 1
Extracting device

page 48
page 58
20 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
5870.300.019 1
Extracting device

page 48
page 58
5873.012.013 1
Rapid grip

page 48
page 58
5870.300.035 1
Extracting device

page 48
page 58
5870.204.022 1 1 set = 2 units
Locating pin M14 x 100

page 48
page 58
page 88
page 103
EN 4472.751.001 - 2015-11 21
Workshop Equipment

Designation y
Chapter/section
5870.300.007 1 45 mm – 58 mm
Extracting device

page 48
page 58
5870.300.003 1
Extracting device

page 48
page 58
AA01.305.639 1 Ø14 mm
removing tool

page 48
AA02.038.564 1
Disassembly device

page 58
5873.002.025 1 M95 x 2
Gripping device
22 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
AA02.015.365 1 Suitable for 5870.300.019
Fixing spider
AA02.016.086 1
Plug insert

▪ Install input, page 74
page 86
AA00.640.418 1
Support fixture

page 86
5870.203.002 1 Torque multiplier
Power screwdriver Maximum output torque =

3600 Nm
page 86
5870.240.002 1
Locking mechanism

page 86
EN 4472.751.001 - 2015-11 23
Workshop Equipment

Designation y
Chapter/section
5870.400.001 2
Offset screwdriver
5870.080.044 1
Press-out device
5873.002.051 1 M95 x 2
Gripping device
5870.300.020 1
Extracting device
5870.345.080 1
Assembly fixture
24 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
5870.260.002 1 Length 160 mm
Handle

▪ Assemble differential, page 79
page 88
page 103
5870.056.008 1
Driver tool
5870.204.025 1 1 set = 2 units
Locating pin M14 x 1.5 x 85
AA02.015.690 1
Driver tool
AA02.056.505 1
Pressure piece
EN 4472.751.001 - 2015-11 25
Workshop Equipment

Designation y
Chapter/section
5870.058.070 1
Driver tool

page 81
5870.260.003 1 Length 390 mm
Handle

page 81
AA01.266.870 1 Ø 35 mm – 46 mm
Load-lifting equipment

page 81
AA02.060.628 1
Test device

page 81
5870.048.216 1
Driver tool

page 86
26 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
AA00.593.346 1
M14 x 1.5
Screwing device

page 88
AA02.041.179 1
Driver tool

page 88
page 103
5870.058.061 1
Driver tool

page 88
page 103
5870.200.094 1
Measuring arbor

page 88
page 103
5870.700.004 1 Measuring range

1 to 60 kN
Load cell

page 88
page 103
EN 4472.751.001 - 2015-11 27
Workshop Equipment

Designation y
Chapter/section
AA00.372.127 1
Driver tool

page 88
page 103
AA00.387.830 1
Pressing fixture no.

page 88
page 103
▪ Install tachometer, page 118

with insert.
Assembly fixture
▪ Assembling hub, page 120

with assembly device.
Insert
M22 x 1.5
5870.050.007 1
Driver tool
28 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation y
Chapter/section
5870.260.004 1 Length 230 mm
Handle
5870.345.121 1
Support arbor
AA00.607.922 1
Driver tool
5870.651.085 1
Assembly aid
5870.204.029 1 1 set = 2 units
EN 4472.751.001 - 2015-11 29
Workshop Equipment

Designation y
Chapter/section
5870.204.044 1 1 set = 2 units
▪ Install mounting parts, page 129
7.2 Standard tools and fixtures
To repair this ZF product use the following standard tools and fixtures.
Standard tools:
Figure Order no. Comment

Designation
5870.203.030 0.6 Nm to 6.0 Nm
Torque wrench
5870.203.031 1.0 Nm to 12 Nm
Torque wrench
5870.203.032 3.0 Nm to 23 Nm
Torque wrench
5870.203.033 5.0 Nm to 45 Nm
Torque wrench
Fig. 2 5870.203.034 10 Nm to 90 Nm
Torque wrench
5870.203.039 80 Nm to 400 Nm
Torque wrench
5870.203.016 140 Nm to 750 Nm
Torque wrench
5870.203.011 750 Nm to 2,000 Nm
Torque wrench
5870.203.048 1,500 Nm to 3,000 Nm
Torque wrench
5870.900.013 Contains the sizes:
Set of internal pliers I1, I2, I3, I4
Fig. 3
30 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation
5870.900.014 90° angled, contains the sizes:
Set of internal pliers I11, I21, I31, I41
Fig. 4
5870.900.015 Contains the sizes:
Set of external pliers A1, A2, A3, A4
Fig. 5
5870.900.016 90° angled, contains the sizes:
Set of external pliers A11, A21, A31, A41
Fig. 6
5870.970.001 Jaw width 80 mm
Two-armed extractor Throat depth 100 mm
5870.970.002 Jaw width 120 mm
5870.970.003 Jaw width 170 mm
5870.970.004 Jaw width 200 mm
Fig. 7 5870.970.006 Jaw width 350 mm
5870.970.007 Jaw width 520 mm
Two-armed extractor Throat depth 300 mm to 500 mm
5870.970.026 Jaw width 250 mm
5870.970.028 Jaw width 380 mm
EN 4472.751.001 - 2015-11 31
Workshop Equipment

Designation
5870.971.001 Jaw width 85 mm
Three-armed extractor Throat depth 65 mm
5870.971.002 Jaw width 130 mm
5870.971.003 Jaw width 230 mm
5870.971.004 Jaw width 295 mm
Fig. 8 5870.971.005 Jaw width 390 mm
5870.971.006 Jaw width 640 mm
5870.281.026 Load-bearing capacity 500 kg
Lifting strap Effective length 4 m
Fig. 9
AA02,000,695 Load-bearing capacity 2,000 kg
Round sling Effective length 2 m
Fig. 10
5870.281.047
Lifting chain
Fig. 11
5870.221.500 230V
Hot-air blower
5870.221.501 115V
Hot-air blower
Fig. 12
32 EN 4472.751.001 - 2015-11
Workshop Equipment

Designation
5870.345.071
Pry bar
Fig. 13
5870.280.004
Plastic hammer
5870.280.006 Spare part
Nylon insert
Fig. 14
5870.650.004
Striker
Fig. 15
5870.200.055
Magnetic holder
Fig. 16
5870.200.057
Dial gauge
Fig. 17
EN 4472.751.001 - 2015-11 33
Workshop Equipment

Designation
5870.200.066 Consisting of two pieces
Set of parallel gauge blocks Height 70 mm
5870.200.067 Consisting of two pieces
Set of parallel gauge blocks Height 100 mm
Fig. 18
5870.200.109 Length 150 mm
Digital caliper gauge
Fig. 19
5870.200.072 Length 200 mm
Digital depth gauge
5870.200.114 Length 300 mm
Digital depth gauge
Fig. 20
Tab. 2
Fixture Comment Requirement

Crane with precision hoist Load-bearing capacity min. 1,500 kg
Arbor press Manual operation Press force max. 30 kN
Hydraulic press Hydraulic actuation
Tab. 3
Other Equipment Comment Requirement

Socket wrenches, open-end wrenches, Various sizes, respectively in a set Commercial
box wrenches, hammers, screw drivers,
pliers, front cutting pliers
Sand paper In different grit sizes to clean surfaces
Flat scraper For removal of sealing compound
Whetstone For removal of minor damage and smoothing of plane
faces
Polishing cloth For smoothing and cleaning of surfaces
Foam roller When applying sealing compound
Tab. 4
34 EN 4472.751.001 - 2015-11
Workshop Equipment
7.3 Operating supplies and auxiliary materials
Order no. Manufacturer name Comment

Designation Chapter/section
0666.690.191 Phoenix spirit ▪ Install shaft seal onto the drive, page 86
Spirit
0666.690.313 Loctite 2701 ▪ Install shaft seal onto the drive, page 86
Sealing compound
0666.690.078 Loctite 243 Threadlockers
Sealing compound
▪ Assemble left portal drive, page 88
▪ Install mounting parts, page 129
0666.790.037 Drei Bond Silikon Typ 1207 ▪ Install left portal drive, page 102
Sealing compound
0671.190.065 UNIREX N3 ▪ Install tachometer, page 118
Silicone grease
0671.190.180 Renolit LX‑NHU 2 400 g. package
Grease
EN 4472.751.001 - 2015-11 35
Dismantling
8 Dismantling
8.1 Clamp the axle
Special tools:
▪ 5870.350.093 Fixture
▪ 5870.350.000 Assembly truck
1. Fix axle (1) with 5870.350.093 [Fixture] (2) to

5870.350.000 [Assembly truck] (3). Support
axle from below (4).
Fig. 21
8.2 Drain oil
Observe the environmental regulations (see General safety instructions).
36 EN 4472.751.001 - 2015-11
Dismantling
Fig. 22
1 Screw plug oil level 2 Screw plug oil drain

3 Screw plug oil fill
1. Place suitable containers under the oil drain screw plugs (2).
2. Remove screw plug oil filling (3).

In case of the version with mounted breather, slight overpressure can build up in the axle.
3. Remove screw plug oil level (1) and O‑ring.
4. Remove screw plugs oil drain (2) and O‑ring.
5. Completely drain oil into the containers.
EN 4472.751.001 - 2015-11 37
Dismantling
8.3 Remove mounting parts
1. Loosen hexagon screws (1) and remove the

upper longitudinal control arm (2).
Fig. 23
2. Loosen hexagon screws (1) and remove the

lower longitudinal control arm (2).
Fig. 24
3. Loosen hexagon nut (4) and remove disk (3),

joint ring (2) and disk (1).
4. Remove shock absorber (5).
Fig. 25
38 EN 4472.751.001 - 2015-11
Dismantling
5. Loosen hexagon screw (1).
6. Remove air spring (2).
Fig. 26
7. Fix spring carrier (1) by means of lifting

device.
8. Loosen hexagon screws and remove spring

carrier.
Fig. 27
8.4 Removal of brake
Special tools:
▪ 5870.281.046 Load carrying fixture
▪ 5870.204.084 Eyebolt
Observe the specifications of the brake manufacturer.
EN 4472.751.001 - 2015-11 39
Dismantling
1. Unbolt emergency loosening screw on the

brake cylinder.
Tightening torque: 20 Nm +5 Nm (maximum
loosening torque)
Fig. 28
2. Loosen locknuts.
3. Remove brake cylinder.
Fig. 29
4. Remove rubber cap.
5. Turn adjuster in counterclockwise direction

manually until contact is obtained.
Fig. 30
40 EN 4472.751.001 - 2015-11
Dismantling
6. Remove spring split pin.
7. Remove disk (1) and pin (2).
8. Remove lining bracket (3).
Fig. 31
9. Remove brake lining set.
Fig. 32
10. Fix brake caliper with 5870.281.046 [Load

carrying fixture] (1), 5870.204.084 [Eyebolt]
(2) and crane.
11. Loosen hexagon screws and fit bolt on the

brake caliper.
12. Remove brake caliper.
Fig. 33
EN 4472.751.001 - 2015-11 41
Dismantling
8.5 Remove and dismantle hub.
8.5.1 Remove hub
Special tools:
▪ 5870.345.036 Pry bar
▪ 5870.401.146 Slotted nut wrench
▪ AA01.395.095 Load carrying fixture
1. Fix hub. Loosen bolted connection of the

flange shaft.
Fig. 34
2. Pull out flange shaft with 5870.345.036 [Pry

bar] and remove.
Fig. 35
42 EN 4472.751.001 - 2015-11
Dismantling
3. Remove O‑ring (1) from flange shaft.
Fig. 36
4. Unlock slotted nut.
5. Loosen slotted nut with

5870.401.146 [Slotted nut wrench].
6. Remove retaining plate.
Fig. 37
7. Use AA01.395.095 [Load carrying fixture] to

fix the hub to the crane.
8. Loosen slotted nut with

9. Pull hub from the hub carrier.
Fig. 38
EN 4472.751.001 - 2015-11 43
Dismantling
10. To protect the thread from damage, bolt the

slotted nut (1) flush onto the hub carrier.
Fig. 39
8.5.2 Dismantling hub
Special tools:
▪ 5870.345.036 Pry bar
▪ 5870.100.069 Assembly fixture
1.
Risk of crushing due to hydraulic tool.

Slight to moderate injury possible.
ð Do not reach into danger area.
Use press to fix hub.
2. Loosen Torx screws.
3. Remove hub.
Fig. 40
44 EN 4472.751.001 - 2015-11
Dismantling
4. Remove O-ring.
Fig. 41
5. Use 5870.345.036 [Pry bar] to pull ABS ring

out of the hub and remove it.
Fig. 42
6. Remove retaining ring (1).
7. Remove tapered roller bearing at the brake

disk side from the hub.
Fig. 43
EN 4472.751.001 - 2015-11 45
Dismantling
8. Use 5870.100.069 [Assembly fixture] to press

shaft seal from the tapered roller bearing.
Fig. 44
9. Press tapered roller bearing and shaft seal

from the hub.
Fig. 45
10.
Risk of injury due to parts flying away.

Slight or moderate injury possible.
ð Wear protective goggles.
Force out bearing outer rings.
11. Press wheel studs from the hub.
Fig. 46
46 EN 4472.751.001 - 2015-11
Dismantling
8.6 Remove tachometer
1. Pull cable (1) out of the clamp (2).
2. Remove clamp.
Fig. 47
3. Push tachometer out of the hub carrier.
Fig. 48
4. Push bush out of the hub carrier.
Fig. 49
EN 4472.751.001 - 2015-11 47
Dismantling
8.7 Remove and dismantle left portal drive
8.7.1 Remove left portal drive
Special tools:
▪ AA00.844.345 Load ring
1. Bolt in two pieces AA00.844.345 [Load ring]

(1) onto the portal housing. Loosen Torx
screws and hexagon nuts.
Fig. 50
2.
Risk of injury due to falling parts.

ð Secure parts against falling down.
Remove portal with differential and stub

shaft.
Stub shaft can also be removed from the
right side.
3. Pull stub shaft out of the differential.
4. Pull differential from portal. Fig. 51
5. Remove two pieces AA00.844.345 [Load

ring] (1).
8.7.2 Dismantling left portal drive
Special tools:
▪ 5870.350.110 Connection plate
▪ AA02.041.051 Driver tool
▪ AA01.311.408 Rapid grip
48 EN 4472.751.001 - 2015-11
Dismantling
▪ 5873.002.001 Basic tool

▪ AA02.049.488 Disassembly device
▪ 5870.281.054 Eye nut
▪ 5870.300.009 Extracting device
▪ 5873.012.013 Rapid grip
▪ 5870.204.022 Locating pin
▪ AA01.305.639 removing tool
1. Fix portal drive with

5870.350.110 [Connection plate] to
5870.350.000 [Assembly truck].
Fig. 52
2. Remove retaining ring.
Fig. 53
EN 4472.751.001 - 2015-11 49
Dismantling
3. Remove O‑ring (1).
4. Slide AA02.041.051 [Driver tool] onto the

drive gear (stub shaft).
Fig. 54
5. Pull tapered roller bearing from portal

housing by means of AA01.311.408 [Rapid
grip] and 5873.002.001 [Basic tool].
6. Remove shim.
Fig. 55
7. Slide AA02.049.488 [Disassembly device]

onto the drive gear (stub shaft).
8. Tighten cylindrical screws of

AA02.049.488 [Disassembly device] evenly.
Tightening torque: 68 Nm
9. Use AA02.049.488 [Disassembly device] and

a two-armed puller to pull the drive gear out
of the portal housing.
Fig. 56
50 EN 4472.751.001 - 2015-11
Dismantling
10. Remove parts from the drive gear.
Fig. 57
11. Loosen Torx screws and remove hub carrier

with 5870.281.054 [Eye nut].
Fig. 58
12. Remove O-ring (1).
Fig. 59
EN 4472.751.001 - 2015-11 51
Dismantling
13. Use 5870.300.009 [Extracting device] and

5870.300.019 [Extracting device] to pull the
bearing inner ring out of the hub carrier.
Fig. 60
14. Use a three-armed puller to pull the screen

sheet from the hub carrier.
Fig. 61
15. Remove the output gear from the portal

housing.
Fig. 62
52 EN 4472.751.001 - 2015-11
Dismantling
16. Use 5873.002.001 [Basic tool] and

5873.012.013 [Rapid grip] to pull both
tapered roller bearings from the output gear.
Fig. 63
17. Pull bearing outer ring (1) with

5870.300.035 [Extracting device] out of the
portal housing.
18. Remove shim.
Fig. 64
19. Loosen cylindrical screw.
Fig. 65
EN 4472.751.001 - 2015-11 53
Dismantling
20. Bolt in 5870.204.022 [Locating pin] at the

bearing bolt.
21. Force out and remove bearing bolt.
Fig. 66
22. Remove O‑rings (1).
Fig. 67
23. Hold shaft washer, axial roller cage and disk

(1).
24. Push tapered roller bearing (2) and

intermediate gear outwards and remove the
releasing parts (1).
Fig. 68
54 EN 4472.751.001 - 2015-11
Dismantling
25. Remove tapered roller bearing and

intermediate gear.
Fig. 69
26.

Force bearing inner rings out of the

intermediate gear.
Fig. 70
27. Loosen cylindrical screw on the bearing bolt.

bearing bolt.
Fig. 71
EN 4472.751.001 - 2015-11 55
Dismantling
Fig. 72

intermediate gear.
Fig. 73
32.


intermediate gear.
Fig. 74
56 EN 4472.751.001 - 2015-11
Dismantling

bushes (thrust washers) out of the portal
housing.
Fig. 75
34. Use AA01.305.639 [removing tool] to loosen

the stud bolts.
Fig. 76
8.8 Remove breather
1. Open hose clamp (1).
2. Pull corrugated hose and hose (2) from the

breather neck.
3. Loosen Torx screws (3) and remove breather.
Fig. 77
EN 4472.751.001 - 2015-11 57
Dismantling
8.9 Remove and dismantle right portal drive.
8.9.1 Remove right portal drive
Special tools:

(1) onto the portal housing. Loosen Torx
screws.
Fig. 78
2.

Remove portal and stub shaft.

Stub shaft can also be removed from the
left side.
3. Pull stub shaft from the portal.
4. Remove two pieces AA00.844.345 [Load

ring] (1). Fig. 79
8.9.2 Dismantle right portal drive
Special tools:
▪ AA02.038.564 Disassembly device
▪ 5870.281.054 Eye nut
58 EN 4472.751.001 - 2015-11
Dismantling

▪ 5873.002.001 Basic tool
▪ 5873.012.013 Rapid grip
1. Fix portal drive with

5870.350.110 [Connection plate] to
Fig. 80
Fig. 81
EN 4472.751.001 - 2015-11 59
Dismantling
Fig. 82
4. Insert three-piece tool of

AA02.038.564 [Disassembly device] into the
bush.
Fig. 83
5. Push bush of AA02.038.564 [Disassembly

device] onto the three-piece tool.
Fig. 84
60 EN 4472.751.001 - 2015-11
Dismantling
6. Bolt spindle of AA02.038.564 [Disassembly

device] manually into the three-piece tool.
7. Hold spindle of AA02.038.564 [Disassembly

device]. Turn hexagon nut and pull bush out
of the portal housing.
Fig. 85
8. Remove drive gear and individual parts.
Fig. 86
Fig. 87
EN 4472.751.001 - 2015-11 61
Dismantling
10. Loosen Torx screws and remove hub carrier

with 5870.281.054 [Eye nut].
Fig. 88
11. Remove O-ring (1).
Fig. 89

bearing inner ring out of the hub carrier.
13. Remove shim.
Fig. 90
62 EN 4472.751.001 - 2015-11
Dismantling
14. Use a three-armed puller to pull the screen

sheet from the hub carrier.
Fig. 91
15. Remove the output gear from the portal

housing.
Fig. 92
16. Use 5873.002.001 [Basic tool] and

5873.012.013 [Rapid grip] to pull both
tapered roller bearings from the output gear.
Fig. 93
EN 4472.751.001 - 2015-11 63
Dismantling
17. Pull bearing outer ring (1) with

5870.300.035 [Extracting device] out of the
portal housing.
Fig. 94
Fig. 95

bearing bolt.
Fig. 96
64 EN 4472.751.001 - 2015-11
Dismantling
Fig. 97
22. Hold shaft washer, axial roller cage and disk

(2).
23. Push tapered roller bearing (1) and

intermediate gear outwards and remove the
releasing parts (2).
Fig. 98

intermediate gear.
Fig. 99
EN 4472.751.001 - 2015-11 65
Dismantling
25.


intermediate gear.
Fig. 100
Fig. 101

bearing bolt.
Fig. 102
66 EN 4472.751.001 - 2015-11
Dismantling
Fig. 103

intermediate gear.
Fig. 104
31.


intermediate gear.
Fig. 105
EN 4472.751.001 - 2015-11 67
Dismantling

bushes (thrust washers) out of the portal
housing.
Fig. 106
8.10 Dismantle differential.
Special tools:
▪ 5873.002.025 Gripping device
▪ 5873.002.001 Basic tool
▪ AA02.015.365 Fixing spider
1. Use 5873.002.025 [Gripping device] and

5873.002.001 [Basic tool] to pull off the
tapered roller bearing.
Fig. 107
68 EN 4472.751.001 - 2015-11
Dismantling
2. Use 5870.300.009 [Extracting device],

5870.300.019 [Extracting device] and
AA02.015.365 [Fixing spider] to pull the
bearing outer ring out of the differential.
Fig. 108
3. Fix differential. Loosen locking screws.
Fig. 109
4. Press differential out of the crown wheel.
Fig. 110
EN 4472.751.001 - 2015-11 69
Dismantling
5. Use a striker to remove the bearing outer

ring.
6. Remove shim.
Fig. 111
8.11 Remove input
Special tools:
▪ AA02.016.086 Plug insert
▪ AA00.640.418 Support fixture
▪ 5870.203.002 Power screwdriver
▪ 5870.240.002 Locking mechanism
▪ 5870.400.001 Offset screwdriver
▪ 5870.080.044 Press-out device
▪ 5873.002.051 Gripping device
▪ 5873.002.001 Basic tool
1. Use AA02.016.086 [Plug insert],

AA00.640.418 [Support fixture] and
5870.203.002 [Power screwdriver] to loosen
the double hexagon nut.
Fig. 112
70 EN 4472.751.001 - 2015-11
Dismantling
2. Use 5870.240.002 [Locking mechanism] to

pull the input flange with a three-armed
puller from the pinion.
Fig. 113
3. Press screen sheet from the input flange.
Fig. 114
4. Use 5870.400.001 [Offset screwdriver] to

remove the shaft seal from the axle housing.
Fig. 115
EN 4472.751.001 - 2015-11 71
Dismantling
5. Use 5870.080.044 [Press-out device] to press

the pinion out of the tapered roller bearing
and remove it.
Fig. 116
6. Remove ring.
Fig. 117
7. Use 5873.002.051 [Gripping device] and

5873.002.001 [Basic tool] to pull off the
Fig. 118
72 EN 4472.751.001 - 2015-11
Dismantling

bearing outer ring out of the axle housing.
Fig. 119
9. Use a suitable plate and

5870.080.044 [Press-out device] to press the
bearing outer ring out of the housing.
10. Remove shim.
Fig. 120
11.

Force breather neck out of the axle housing.
Fig. 121
EN 4472.751.001 - 2015-11 73
Assembly
9 Assembly
9.1 Install input
Special tools:
▪ 5870.260.002 Handle
▪ 5870.056.008 Driver tool
1. Read dimension U (1) from the axle housing.

Dimension U = e. g. 201.20 mm
Fig. 122
2. Compare mating number (1) e. g. "17" with

mating number on the crown wheel. Both
mating numbers must be identical.
3. Read pinion distance deviation (2).

Pinion distance deviation A = e. g. "+5" =
0.05 mm
Fig. 123
74 EN 4472.751.001 - 2015-11
Assembly
4. Read pinion basic dimension (1).

Pinion basic dimension B = e. g. 150 mm
Fig. 124
5. Roll in the large pinion bearing.
6. Measure bearing width of the large pinion

bearing.
Bearing width C = e. g. 50.05 mm
7. Calculate thickness s of the shim.
Calculation example:
s = U – (A + B + C)
s = 201.20 mm –
(0.05 mm + 150 mm + 50.05 mm)
s = 1.1 mm
Fig. 125
8. Carry out the following two work steps

immediately one after the other.
Risk of burn injuries due to contact with cold

surface.
ð Wear protective gloves.
Undercool the bearing outer ring.
9. Insert the bearing outer ring into the axle

housing until contact is obtained. Fig. 126
EN 4472.751.001 - 2015-11 75
Assembly
10. Insert the shim (2) into the bearing hole.
11. Carry out the following three work steps

Risk of burn injuries due to contact with cold

surface.
Undercool the bearing outer ring (1).

Fig. 127
12. Insert bearing outer ring (1) into axle housing
until contact is obtained.
13. Use 5870.345.080 [Assembly fixture] to bring

both bearing outer rings into contact position.
Fig. 128
14. Press on the bearing inner ring until contact

with the pinion is obtained.
Fig. 129
76 EN 4472.751.001 - 2015-11
Assembly
15. Push ring with e. g. s = 10.30 mm onto the

pinion.
Fig. 130
16.
Risk of burn injuries due to contact with hot

surfaces.
Heat tapered roller bearing.
17. Insert pinion into the axle housing from

inside. Slide the heated tapered roller bearing
onto the pinion until contact is obtained.
Fig. 131
18. If available, insert the hexagon screws into

the input flange.
19. Use 5870.260.002 [Handle] and

5870.056.008 [Driver tool] to press the
screen sheet onto the input flange.
Fig. 132
EN 4472.751.001 - 2015-11 77
Assembly
20.

surfaces.
Heat input flange.
21. Slide input flange onto the pinion until

contact is obtained.
Fig. 133

5870.203.002 [Power screwdriver] to tighten
the double hexagon nut removed during
disassembly.
Tightening torque: 1,000 Nm
Fig. 134
23. Rotate pinion several times in both directions.
24. Check the necessary pinion bearing rolling

torque 4 Nm – 10 Nm.
25. If the rolling torque is too small, retighten the

double hexagon nut, until the necessary
rolling torque is reached.
Tightening torque: 1,000 Nm – 1,700 Nm
▪ In case of an insufficient rolling
torque, install a thinner ring.
▪ In case of an excessive rolling torque,
install a thicker ring.
Fig. 135
26. Note down the applied tightening torque and
adjusted rolling torque.
78 EN 4472.751.001 - 2015-11
Assembly
9.2 Assemble differential
Special tools:
▪ 5870.260.002 Handle
▪ AA02.056.505 Pressure piece
1. Compare mating number (1) e. g. "17" with

mating number on the crown wheel. Both
mating numbers must be identical.
2. Note ideal backlash (1) e. g. "0.22" [mm].
Fig. 136
3. Bolt in two pieces 5870.204.025 [Locating

pin] into the crown wheel.
4.

surfaces.
Heat crown wheel.
5. Slide crown wheel onto the differential until

contact is obtained. Fig. 137
EN 4472.751.001 - 2015-11 79
Assembly
6. Tighten screws, if the parts have max.

30 °C.
Fix differential. Bolt in New Locking screws

and tighten crosswise.
Fig. 138
7. Insert bearing outer ring with

AA02.015.690 [Driver tool] and
5870.260.002 [Handle] until contact is
obtained.
Fig. 139
8. Press in bearing inner ring with

AA02.056.505 [Pressure piece] until contact
is obtained.
Fig. 140
80 EN 4472.751.001 - 2015-11
Assembly
9.3 Setting backlash and differential bearing rolling torque and checking axial run-out and contact
pattern.
Special tools:
▪ 5870.058.070 Driver tool
▪ 5870.260.003 Handle
▪ AA01.266.870 Load-lifting equipment
▪ AA02.060.628 Test device
Setting backlash
1. Insert shim with s = e. g. 1 mm into the axle

housing.
2. Use 5870.058.070 [Driver tool] and

5870.260.003 [Handle] to insert the bearing
outer ring.
Fig. 141
3. Cover several drive and coast flanks on the

crown wheel with marking ink.
4.
Risk of crushing due to moving load.

ð Move load slowly and carefully.
ð Do not reach into danger area!
Use AA01.266.870 [Load-lifting equipment]

to insert the differential into the axle housing.
Fig. 142
EN 4472.751.001 - 2015-11 81
Assembly
5. Slide bearing inner ring (1) onto

AA02.060.628 [Test device].
Fig. 143
6. Put AA02.060.628 [Test device] onto the axle

housing.
7. Install AA02.060.628 [Test device] evenly

with cylindrical screws until contact is
obtained.
8. Tighten cylindrical screws crosswise.

9. Turn pinion:
▪ Speed: 50 1/min
▪ Duration (always left and right): 15 s
Fig. 144
10. Place dial gauge at right-angled surface of a

hexagon screw at the differential.
11. Backlash bevel gear set

e. g. 0.22 mm (±0.04 mm) Check (see
Reassemble differential).
If the required backlash is not reached,
replace the disk as specified below:
▪ In case of an insufficient backlash,
install a thicker shim.
▪ In case of an excessive backlash,
install a thinner disk.
Fig. 145
82 EN 4472.751.001 - 2015-11
Assembly
Checking axial run-out.
12. Place dial gauge to the crown wheel rear

side.
13. Turn input flange and check Axial run-out

crown wheel max. 0.08 mm.
If the permitted axial run-out is not
observed, check and correct contact of
the crown wheel.
Fig. 146
Setting rolling torque differential bearing and checking contact pattern.
14. Measure distance from the front face of the

AA02.060.628 [Test device] to the front face
of the bearing inner ring. Measure distance of
each hole and calculate average.
Distance A = e. g. 59.44 mm
Fig. 147
15. Remove AA02.060.628 [Test device].
16. Use AA01.266.870 [Load-lifting equipment]

to remove the differential from the axle
housing.
17. Check contact pattern (See Check contact

pattern).
Correct deviations from the contact
pattern.
If the shim for the contact pattern is

changed, proceed as follows:
▪ Adapt ring for the rolling torque Fig. 148
EN 4472.751.001 - 2015-11 83
Assembly
▪ Check rolling torque
18. Read height of the AA02.060.628 [Test device] from the plane face of the AA02.060.628 [Test
device].
Height of the AA02.060.628 [Test device] = e. g. 84.7 mm
19. Calculate distance from axle housing to front face of the bearing inner ring.
Distance X = height of the AA02.060.628 [Test device]– distance A
Distance X = 84.7 mm – 59.44 mm
Distance X = 25.26 mm
20. Measure distance from the mounting face of

the portal housing to the contact face of the
bearing inner ring.
Distance C = e. g. 26.26 mm
21. Calculate shim thickness for Differential

bearing rolling torque 4 Nm – 7 Nm.
s = Distance C – Distance X
s = 26.26 mm – 25.26 mm
s = 1.00 mm
Fig. 149
22. Slide the calculated shim (2) onto the bearing

seat.
23.

surfaces.
Heat tapered roller bearing.
24. Slide on bearing inner ring (1) until contact is

obtained. Fig. 150
25. Adjust bearing inner ring (1) after cooling-

down.
84 EN 4472.751.001 - 2015-11
Assembly
26. Use AA01.266.870 [Load-lifting equipment]

to insert the differential into the axle housing.
Fig. 151
27. Place portal housing onto the axle housing with two pieces AA00.844.345 [Load ring] (1).
28. Fix portal housing with three Torx screws.

29.

Also, secure the portal housing with a crane.
30. Rotate input flange several times into both directions.
31. Check total rolling torque.

Total rolling torque at axle ratio i < 7.38
Total rolling torque = Pinion bearing rolling torque + 2 Nm (±1 Nm)
Total rolling torque at axle ratio i > 7.38
Total rolling torque = Pinion bearing rolling torque + 1.5 Nm (±0.5 Nm)
If the required rolling torque is not achieved, replace the disk as specified below:
▪ In case of an insufficient rolling torque, install a thicker shim.
▪ In case of an excessive rolling torque, install a thinner shim.
32. Remove portal housing.
33. Use AA01.266.870 [Load-lifting equipment] to remove the differential from the axle housing.
EN 4472.751.001 - 2015-11 85
Assembly
9.4 Install shaft seal onto the drive
Special tools:
▪ 5870.240.002 Locking mechanism
▪ 5870.048.216 Driver tool
Operating supplies and auxiliary materials:

▪ 0666.690.191 Spirit
▪ 0666.690.313 Sealing compound

5870.203.002 [Power screwdriver] to loosen
Fig. 152
2. Use 5870.240.002 [Locking mechanism] to

pull the input flange with a three-armed
puller from the pinion.
Fig. 153
86 EN 4472.751.001 - 2015-11
Assembly
3. Carry out the following two work steps

Apply 0666.690.191 [Spirit ] to the outer

diameter of the shaft seal.
4. Use 5870.048.216 [Driver tool] to insert the

shaft seal with the seal lip showing to the oil
chamber.
Fig. 154
5. If the double hexagon nut was already

bolted in, apply
0666.690.313 [Sealing compound] onto
the thread.
Use AA02.016.086 [Plug insert],

5870.203.002 [Power screwdriver] to tighten
Fig. 155
6. Rotate pinion several times in both directions.
7. Check the necessary Pinion bearing rolling

torque 4.5 Nm – 10.5 Nm.
8. If the rolling torque is too small, retighten the

double hexagon nut, until the necessary
rolling torque is reached.
Tightening torque: 1,000 Nm – 1,700 Nm
Fig. 156
EN 4472.751.001 - 2015-11 87
Assembly
9.5 Assemble and install left portal drive
9.5.1 Assemble left portal drive
Special tools:
▪ AA00.593.346 Screwing device
▪ 5870.260.002 Handle
▪ 5870.058.061 Driver tool
▪ 5870.200.094 Measuring arbor
▪ 5870.700.004 Load cell
▪ 5870.281.054 Eye nut
▪ AA00.387.830 Pressing fixture no.

1. Use 5870.350.110 [Connection plate] to fix

the portal housing to
Fig. 157
88 EN 4472.751.001 - 2015-11
Assembly
2. Apply 0666.690.078 [Sealing compound] to

the short thread of the stud bolts.
3. Use AA00.593.346 [Screwing device] to bolt

the stud bolts with the short side to the portal
housing.
Fig. 158
4. Use AA02.041.179 [Driver tool] and

5870.260.002 [Handle] to insert the bushes
(thrust washers) into the portal housing.
Fig. 159
5. In case of used bearings, always

allocate the bearing inner rings to the
respective bearing outer rings.
Slide the tapered roller bearing onto the

bearing bolt.
Fig. 160
EN 4472.751.001 - 2015-11 89
Assembly

inner rings into the intermediate gear.
Fig. 161
7. Put the intermediate gear onto the tapered

roller bearing.
Fig. 162
8. Slide the tapered roller bearing onto the

bearing bolt.
Fig. 163
90 EN 4472.751.001 - 2015-11
Assembly
9. Put shim with e. g. s = 2.80 mm onto the

bearing bolt.
Fig. 164
10. Rotate intermediate gear several times and

use 5870.200.094 [Measuring arbor] and a
press to preload with 10 kN.
11. Place dial gauge at the inner surface.
12. Evenly lift the intermediate gear with a pry

bar and check the necessary setting of the
intermediate gear bearing 0.01 mm preload–
0.05 mm clearance.
If the required axial play is not reached,
replace the shim as specified below:
▪ In case of an insufficient axial play,
install a thicker shim. Fig. 165
▪ In case of an excessive axial play,
install a thinner shim.
13. Mark the installation position of the individual

parts.
14. Dismantle the individual parts.
EN 4472.751.001 - 2015-11 91
Assembly
15. Insert the tapered roller bearing into the

portal housing.
16. Insert the intermediate gear into the portal

housing.
Fig. 166

intermediate gear.
18. Place intermediate gear and tapered roller

bearing onto a bush (thrust washer) in the
portal housing.
Fig. 167
19. Grease O‑rings (1) and insert them into the

annular grooves.
20. Glue the determined shim (2) with grease

onto the bearing bolt.
21. Bolt 5870.204.022 [Locating pin] (3) into the

bearing bolt.
Fig. 168
92 EN 4472.751.001 - 2015-11
Assembly
22. Slide the bearing bolt into the portal housing

and fix intermediate gear and tapered roller
bearing.
23. Remove 5870.204.022 [Locating pin].
Fig. 169
24. Fix bearing bolt with a cylindrical screw.

Fig. 170
25. Set the bearing of the second intermediate gear as illustrated.

portal housing.

housing.
Fig. 171
EN 4472.751.001 - 2015-11 93
Assembly

intermediate gear.

portal housing.
Fig. 172
30.
Damage due to wrong arrangement of the

parts possible.
ð Observe installation position of the
individual parts.
Put the roller cage onto the shaft washer.

Radius or chamfer on the internal diameter of
the shaft washer must be opposite of the
roller cage.
Fig. 173
31. Place disk with radius or chamfer on the

outer diameter showing upwards onto the
roller cage.
Fig. 174
94 EN 4472.751.001 - 2015-11
Assembly
32. Place cup spring with the concave side

showing downwards onto the disk.
Fig. 175
33. Insert the stacked parts with the cup spring

showing upwards into the hole on the portal
housing (1) and hold them.
34. Place tapered roller bearing and intermediate

gear (2) in such a way that the stacked parts
are fixed in the hole (1).
Fig. 176

annular grooves.


bearing bolt.
Fig. 177
EN 4472.751.001 - 2015-11 95
Assembly

bearing.
Fig. 178

Fig. 179
41. Place shaft washer (4) onto the drive gear.
42. Place the axial roller cage (3) onto the drive
gear.
43. Place disk (2) onto the drive gear.
44. Place cup spring (1) with the concave side

showing downwards onto the drive gear.
Fig. 180
96 EN 4472.751.001 - 2015-11
Assembly
45. Insert the drive gear into the portal housing.

Thereby take up the shaft washer with the
pin on the drive gear.
Fig. 181
46. Evenly support the portal housing on the

hydraulic press from below at the edges (1).
47. Place the bush (2) with the groove showing

downwards onto the portal housing.
48.

Press the bush (2) with max. 60 kN by using

AA02.041.051 [Driver tool] (3) and Fig. 182
5870.700.004 [Load cell] (4) into the
housing.
49. Insert retaining ring.
Fig. 183
EN 4472.751.001 - 2015-11 97
Assembly
50. Press bearing outer rings onto the output

gear.
Fig. 184
51. Place the bearing outer rings onto the

52. Set Output gear bearing 0.03 mm preload–

0.03 mm clearance
Always put a suitable ring under the lower
bearing outer ring and onto the upper
bearing outer ring.
53. Measure total height of output gear, tapered

roller bearing and rings.
Total height A = e. g. 165.05 mm
Fig. 185
54. Measure height of the rings.

Total height of the rings B = e. g. 30.00 mm
55. Calculate total height of output gear and

C=A–B
C = 165.05 mm – 30.00 mm
C = 135.05 mm
Fig. 186
98 EN 4472.751.001 - 2015-11
Assembly
56. Measure dimension from mounting face to

hole bottom.
Housing depth = e. g. 180.83 mm
Fig. 187

hole bottom.
Dimension F = e. g. 44.68 mm
s = Housing depth D – Dimension F – Total
height output gear and tapered roller
bearing C
s = 180.83 mm – 44.68 mm – 135.05 mm
s = 1.1 mm
Fig. 188
59. Insert the determined shim.

outer ring.
Fig. 189
EN 4472.751.001 - 2015-11 99
Assembly

outer ring.
Fig. 190
62. Place the output gear into the portal housing.
Fig. 191
63. Grease the O‑ring and insert it into the

annular groove on the hub carrier (1).
Fig. 192
100 EN 4472.751.001 - 2015-11

Assembly
64. Place hub carrier with 5870.281.054 [Eye

nut] and crane onto the portal housing.
Fig. 193
65. Fix hub carrier with Torx screws.

Fig. 194
66. Put the screen sheet onto the hub carrier.
67. Align the recess of the screen sheet on the

boss of the hub carrier.
68. Align the recess of the

AA00.387.830 [Pressing fixture no.] on the
69. Use AA00.387.830 [Pressing fixture no.] to

force the screen sheet onto the hub carrier.
Fig. 195
EN 4472.751.001 - 2015-11 101

Assembly
9.5.2 Install left portal drive
Special tools:

1.
Risk of crushing due to moving load.

ð Move load slowly and carefully.
ð Do not reach into danger area!
Slide differential onto the drive gear.
2. Apply 0666.790.037 [Sealing compound] (1)

onto the portal housing.
3. Grease O‑ring (2) and insert it into the

annular groove on the portal housing. Fig. 196

(1) onto the portal housing.
Fig. 197
102 EN 4472.751.001 - 2015-11

Assembly
5. Support axle from below.
6. Push differential into the axle housing and

bring portal housing into contact position
with the axle housing.
7. Fix portal drive with Torx screws.

Fix portal drive with hexagon nuts.
Fig. 198
9.6 Assemble and install right portal drive
9.6.1 Assemble right portal drive
Special tools:
▪ 5870.260.002 Handle
▪ 5870.058.061 Driver tool
▪ 5870.700.004 Load cell
▪ 5870.200.094 Measuring arbor
▪ 5870.281.054 Eye nut
1. Use 5870.350.110 [Connection plate] to fix

the portal housing to
Fig. 199
EN 4472.751.001 - 2015-11 103

Assembly

5870.260.002 [Handle] to insert the bushes
(thrust washers) into the portal housing.
Fig. 200

bearing bolt.
Fig. 201

inner rings into the intermediate gear.
Fig. 202
104 EN 4472.751.001 - 2015-11

Assembly
5. Put the intermediate gear onto the tapered

roller bearing.
Fig. 203

bearing bolt.
Fig. 204
7. Put shim with e. g. s = 2.80 mm onto the

bearing bolt.
Fig. 205
EN 4472.751.001 - 2015-11 105

Assembly
8. Rotate the intermediate gear several times

and use 5870.700.004 [Load cell],
5870.200.094 [Measuring arbor] and a press
to preload the bearing with 10 kN.
9. Place dial gauge at the inner surface.
10. Evenly lift the intermediate gear with a pry

bar and check the necessary setting of the
intermediate gear bearing 0.01 mm preload–
0.05 mm clearance.
If the required axial play is not reached,
replace the shim as specified below:
▪ In case of an insufficient axial play, Fig. 206
install a thicker shim.
▪ In case of an excessive axial play,
install a thinner shim.
11. Mark the installation position of the individual

parts.
12. Dismantle the individual parts.

portal housing.

housing.
Fig. 207
106 EN 4472.751.001 - 2015-11

Assembly

intermediate gear.

portal housing.
Fig. 208

annular grooves.


bearing bolt.
Fig. 209

bearing.
Fig. 210
EN 4472.751.001 - 2015-11 107

Assembly

Fig. 211
23. Set the bearing of the second intermediate gear as illustrated.

portal housing.

housing.
Fig. 212

intermediate gear.

portal housing.
Fig. 213
108 EN 4472.751.001 - 2015-11

Assembly
28.
Damage due to wrong arrangement of the

parts possible.
ð Observe installation position of the
individual parts.
Put the roller cage onto the shaft washer.

Radius or chamfer on the internal diameter of
the shaft washer must be opposite of the
roller cage.
Fig. 214
29. Place disk with radius or chamfer on the

outer diameter showing upwards onto the
roller cage.
Fig. 215
30. Place cup spring with the concave side

showing downwards onto the disk.
Fig. 216
EN 4472.751.001 - 2015-11 109

Assembly
31. Insert the stacked parts with the cup spring

showing upwards into the hole on the portal
housing (2) and hold them.
32. Place tapered roller bearing and intermediate

gear (1) in such a way that stacked parts in
the (2) hole are fixed.
Fig. 217

annular grooves.


bearing bolt.
Fig. 218

bearing.
Fig. 219
110 EN 4472.751.001 - 2015-11

Assembly

Fig. 220
Fig. 221
40. Place shaft washer (4) onto the drive gear.

Thereby the retaining ring in the drive gear
must show downwards.
41. Place the axial roller cage (3) onto the drive
gear.
42. Place disk (2) onto the drive gear.
43. Place cup spring (1) with the concave side

showing downwards onto the drive gear.
44. Push drive gear and individual parts into the

portal housing.
Fig. 222
EN 4472.751.001 - 2015-11 111

Assembly
45. Evenly support the portal housing on the

hydraulic press from below at the edges (1).
46. Place the bush (2) with the groove showing

downwards onto the portal housing.
47.

Press the bush (2) with max. 60 kN by using

AA02.041.051 [Driver tool] (3) and Fig. 223
5870.700.004 [Load cell] (4) into the
housing.
Fig. 224
49. Press bearing outer rings onto the output

gear.
Fig. 225
112 EN 4472.751.001 - 2015-11

Assembly
50. Place the bearing outer rings onto the

51. Set Output gear bearing 0.03 mm preload–

0.03 mm clearance
Always put a suitable ring under the lower
bearing outer ring and onto the upper
bearing outer ring.
52. Measure total height of output gear, tapered

roller bearing and rings.
Total height A = e. g. 165.05 mm
Fig. 226
53. Measure height of the rings.

Total height of the rings B = e. g. 30.00 mm
54. Calculate total height of output gear and

C=A–B
C = 165.05 mm – 30.00 mm
C = 135.05 mm
Fig. 227

hole bottom.
Housing depth = e. g. 180.83 mm
Fig. 228
EN 4472.751.001 - 2015-11 113

Assembly

hole bottom.
Dimension F = e. g. 44.68 mm
s = Housing depth D – Dimension F – Total
height output gear and tapered roller
bearing C
s = 180.83 mm – 44.68 mm – 135.05 mm
s = 1.1 mm
Fig. 229
58. Insert the determined shim.

outer ring.
Fig. 230

outer ring.
Fig. 231
114 EN 4472.751.001 - 2015-11

Assembly
61. Place the output gear into the portal housing.
Fig. 232
62. Grease the O‑ring and insert it into the

annular groove on the hub carrier (1).
Fig. 233
63. Place hub carrier with 5870.281.054 [Eye

nut] and crane onto the portal housing.
Fig. 234
EN 4472.751.001 - 2015-11 115

Assembly
64. Fix hub carrier with Torx screws.

Fig. 235
65. Put the screen sheet onto the hub carrier.
66. Align the recess of the screen sheet on the


68. Use AA00.387.830 [Pressing fixture no.] to

force the screen sheet onto the hub carrier.
Fig. 236
9.6.2 Install right portal drive
Special tools:
116 EN 4472.751.001 - 2015-11

Assembly

(1) onto the portal housing.
2. Grease the O‑ring (2) and insert it into the

annular groove on the portal housing.
3. Push the stub shaft with the pin showing

inwards into the drive gear of the portal drive.
Thereby take up the shaft washer with the
pin on the drive gear.
4. Push the stub shaft into the axle housing and

bring the portal housing into contact position
with the axle housing.
Fig. 237
5. Support axle from below (1).
6. Fix portal drive with Torx screws.

Fig. 238
9.7 Install breather neck
1. Push the breather neck into the hole on the

axle housing so that an edge of the hexagon
is parallel to the portal housing.
2.

Force the breather neck with a sleeve or a

tube into the axle housing.
Fig. 239
EN 4472.751.001 - 2015-11 117

Assembly
9.8 Install breather
1. Fix the breather on the axle housing with Torx

screws (3).
2. Push the hose clamp (1) onto the hose.
3. Push the hose (2) onto the breather neck.
4. Secure hose (2) with hose clamp (1).
Fig. 240
9.9 Install tachometer
Special tools:

▪ 0671.190.065 Silicone grease
1. Push bush (1) into the hub carrier.
Fig. 241
118 EN 4472.751.001 - 2015-11

Assembly
2. For the installation dimension refer to

the current spare parts lists.
Apply a thin layer of

0671.190.065 [Silicone grease] outside to the
tachometer.
3. Push the tachometer into the bush so that

approx. 1 mm protrudes from the contact
face of the compact bearing.
Fig. 242

boss of the hub carrier. Push
AA00.387.830 [Pressing fixture no.] slowly
until contact position with the hub carrier and
position the tachometer.
Fig. 243
5. Push the clamp (2) into the hole on the

screen sheet, until engagement of the
securing clips.
6. Push the cable (1) into the clamp (2).
Fig. 244
EN 4472.751.001 - 2015-11 119

Assembly
9.10 Assemble and install hub
9.10.1 Assembling hub
Special tools:
▪ 5870.610.002 Insert
▪ 5870.050.007 Driver tool
▪ 5870.260.004 Handle
▪ 5870.345.121 Support arbor
1. Use the tools only with hubs where

wheel studs have already been installed.
Use 5870.610.010 [Assembly fixture] and

5870.610.002 [Insert] to install the wheel
studs.
Fig. 245

5870.260.004 [Handle] to press both bearing
outer rings into the hub until contact is
obtained.
Fig. 246
120 EN 4472.751.001 - 2015-11

Assembly
3. Apply 125 – 150 g Grease (1) according to

ZF List of Lubricants TE‑ML 12 into the 1
compact bearing (4). Press grease also from
outside (Pfeile) into the space between
bearing inner ring and bearing cage.
3
2
40_020226_01
Fig. 247
1 Grease
2 O‑ring
3 Retaining ring
4 Compact bearing (consisting of two individual tapered
roller bearings)
4. Place bearing inner ring at the brake disk side

onto 5870.345.121 [Support arbor].
5. Insert the retaining ring into the bearing inner

ring at the brake disk side.
Fig. 248
EN 4472.751.001 - 2015-11 121

Assembly
6. Place the hub onto the bearing inner ring at

the brake disk side.
7. Place the outer bearing inner ring into the

hub.
Fig. 249
8. Press the outer bearing inner ring slowly

downwards, until engagement of the
retaining ring is audible.
9. Rotate hub several times in both directions.
Fig. 250
10. Check whether the retaining ring (1) is

completely engaged.
Fig. 251
122 EN 4472.751.001 - 2015-11

Assembly
11. Use AA00.607.922 [Driver tool] to insert the

outer shaft seal.
Fig. 252
12. Use AA00.607.922 [Driver tool] to insert the

shaft seal at the brake disk side.
Fig. 253
13. Put hub onto the brake disk.
14.

Use press to fix hub.
15. Screw in Torx screws and tighten.

Fig. 254
EN 4472.751.001 - 2015-11 123

Assembly

annular groove on the compact bearing.
Fig. 255
9.10.2 Install hub
Special tools:
▪ 5870.651.085 Assembly aid
▪ AA01.395.095 Load carrying fixture
▪ 5870.401.146 Slotted nut wrench

▪ 0671.190.180 Grease
1. Push 5870.651.085 [Assembly aid] (1) into

the hub carrier.
2. Apply 0671.190.180 [Grease] evenly onto

both bearing seats (2).
Fig. 256
124 EN 4472.751.001 - 2015-11

Assembly
3. Use AA01.395.095 [Load carrying fixture] to

fix the hub to the crane.
4. Push hub carefully onto the hub carrier.
5. Bolt on slotted nut with the chamfer showing

outwards.
6. Tighten slotted nut with

7. Rotate hub several times in both directions.

Fig. 257
9. Mount locking plate with the tab showing

inwards onto the hub carrier.
10. Bolt on slotted nut with the chamfer showing

inwards.

Fig. 258
EN 4472.751.001 - 2015-11 125

Assembly
12. Secure slotted nut with locking plate (1).
Fig. 259

annular groove on the flange shaft.
Fig. 260
14. Bolt two pieces 5870.204.029 [Locating pin]

into the hub.
15. Push flange shaft into the hub carrier.
Fig. 261
126 EN 4472.751.001 - 2015-11

Assembly
16. Bolt in screws and tighten.

Alternatively tighten screws with
actuated brake.
Fig. 262
9.11 Install brake
Special tools:
▪ 5870.281.046 Load carrying fixture
▪ 5870.204.084 Eyebolt
Observe the specifications of the brake manufacturer.
1. Use 5870.281.046 [Load carrying fixture] (1),

5870.204.084 [Eyebolt] (2) and crane to
place the brake caliper onto the hub carrier
(brake carrier).
2. Screw in fit bolt at the front in driving

direction and tighten.
3. Turn in hexagon screws and tighten.

Fig. 263
EN 4472.751.001 - 2015-11 127

Assembly
4. Insert brake lining set into the brake caliper.
Fig. 264
5. Attach lining bracket (3) into the brake.
6. Press lining bracket (3) downwards and push

pin (2) into the opposite driving direction into
the hole on the brake caliper.
7. Push disk (1) onto pin (2).
8. Fix pin (2) with spring split pin.
Fig. 265
9. Mount brake cylinder with the connections

showing backwards to the brake caliper.
10. Fix brake cylinder with new locknuts.

Tightening torque: 195 Nm (±15 Nm)
Fig. 266
128 EN 4472.751.001 - 2015-11

Assembly
11. Bolt in emergency loosening screw at the

brake cylinder.
Tightening torque: 20 Nm (+5 Nm)
Fig. 267
9.12 Install mounting parts
Special tools:

1. Screw in two units 5870.204.044 [Locating

pin].
2. Fix spring carrier (1) by means of lifting

device.
3. Push on spring carrier (1) and align in

horizontal position.
4. Manually bolt in two screws with disks into

the axle.
5. Remove two pieces 5870.204.044 [Locating

pin].
Fig. 268
6. Manually bolt in two screws with disks into

the axle.
7. Tighten hexagon screws.

EN 4472.751.001 - 2015-11 129

Assembly
8. Place air spring (2) onto the spring carrier.
9. Apply 0666.690.078 [Sealing compound]

onto the thread of the hexagon screw (1).
10. Fix air spring (2) with hexagon screw (1).

Fig. 269
11. Connect shock absorber (5) to the spring

carrier.
12. Push disk (1), joint ring (2) and disk (3) at the
thread of the shock absorber.
13. Fix shock absorber with hexagon nut (4).

Fig. 270
14. Horizontally suspend the lower longitudinal

control arm (2) with the lifting device.
15. Fix the lower longitudinal control arm (2) with

hexagon screws (1).
Fig. 271
130 EN 4472.751.001 - 2015-11

Assembly
16. Horizontally suspend the upper longitudinal

control arm (2) with the lifting device.
17. Fix the upper longitudinal control arm (2)

with hexagon screws (1).
Fig. 272
9.13 Filling oil
Observe the environmental regulations (see General safety instructions).
Fig. 273
1 Screw plug oil level 2 Screw plug oil drain

3 Screw plug oil fill
EN 4472.751.001 - 2015-11 131

Assembly
1. Push O-rings onto the screw plugs.
2. Screw in screw plugs oil drain (2) and tighten.

3.
The use of a non-approved lubricant can lead to property damage.

ð Only use lubricant from the currently valid ZF List of Lubricants.
Slowly fill in oil at the oil filling hole until the bottom edge of the oil level hole (1) is reached.
4. Check oil level after some minutes and correct if necessary.
5. Screw in screw plug oil filling (3) and tighten.

6. Turn in screw plug oil level (1) and tighten.

132 EN 4472.751.001 - 2015-11

Testing, Measuring, Adjusting
10 Testing, Measuring, Adjusting
10.1 Check contact pattern
Ideal contact pattern of the crown wheel.
Fig. 274 Ideal contact pattern

Left Crown wheel convex (drive side) Right Crown wheel concave (coast side)
1 Ideal contact pattern 2 Toe
3 Heel
The possible deviations and required correction measures are described in the following sections.
EN 4472.751.001 - 2015-11 133

10.1.1 Contact pattern on crown wheel shifted towards the root
Requirements:
▪ Contact pattern is shifted towards the root
Fig. 275 Tooth root contact
1 Contact pattern too close to the root 2 Toe
3 Heel
1. Insert a thinner pinion distance disk on the drive.
2. Setting backlash
3. Check contact pattern.
134 EN 4472.751.001 - 2015-11

10.1.2 Contact pattern on the crown wheel shifted towards the tip
Requirements:
▪ Contact pattern is shifted towards the tip
Fig. 276 Tooth tip contact
1 Contact pattern too close at the tip 2 Toe
3 Heel
1. Insert a thicker pinion distance disk on the drive.
2. Setting backlash
3. Check contact pattern.
EN 4472.751.001 - 2015-11 135

Annex
11 Annex
11.1 Overview of revisions
Index Date of issue Initiator Chapter/Section Comment

11.2015 — — First edition
Tab. 5
136 EN 4472.751.001 - 2015-11

ZF Friedrichshafen AG
ZF Services
Donaustraße 71
94034 Passau
Deutschland · Germany
Telefon/Phone +49 851 494-0
Telefax/Fax +49 851 494-905 000
www.zf.com
EN 4472.751.001 - 2015-11

4472.751.101 Repair Instructions AV-110 & AV-133

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

4472.751.101 Repair Instructions AV-110 & AV-133

Hochgeladen von

Copyright:

Verfügbare Formate

REPAIR INSTRUCTIONS

This document is protected by copyright.

2 Safety Instructions ...................................................................................................... 6

3 Notes on Repairs and Assembly ................................................................................. 10

4 Technical Data ............................................................................................................ 13

5 Setting Data ............................................................................................................... 14

6 Tightening Torques ..................................................................................................... 15

7 Workshop Equipment ................................................................................................. 17

8.10 Dismantle differential. ...................................................................................................................... 68

10 Testing, Measuring, Adjusting ..................................................................................... 133

11 Annex ......................................................................................................................... 136

Object of documentation is a ZF product. State of design acc. to date of issue.

1.1 Document overview

Document no. Designation Technical information

2.1 General safety instructions

Repair, assembly, maintenance, and commissioning

Handling operating supplies and auxiliary materials

Pay attention to the manufacturer's regulations and accident prevention regulations.

2.2 Signal words and symbols

The following symbols are additionally used:

This symbol refers to additional, safety-relevant information.

3 Notes on Repairs and Assembly

3.1 General notes

▪ Please read this documentation prior to starting repair or assembly work.

3.2 Cleaning the ZF product

Possible damage to ZF product due to water infiltration.

3.3 Dismantling the ZF product

3.4 Assembling the ZF product

3.5 Cleaning parts

▪ Clean all reusable parts.

3.6 Reusing parts

3.7 Replacing parts

The following parts must always be replaced:

3.8 Reworking parts

Authorized, specialized staff assess whether parts need to be reworked.

Minor damage includes:

4.1 Oil grade

Damage to ZF product due to incorrect oil possible.

Observe the information on the type plate.

4.2 Type plate

The type plate contains the most important data.

Fig. 1 Type plate

Designation Dimensions Measuring Comment

▪ Setting backlash and differential

Designation Tightening torque Measuring Comment

Designation Tightening torque Measuring Comment

7.1 Special tools

Figure Order no. Quantit Comment

▪ Clamp the axle, page 36

▪ Clamp the axle, page 36

Load carrying fixture

▪ Removal of brake, page 39

▪ Removal of brake, page 39

Figure Order no. Quantit Comment

▪ Remove hub, page 42

Slotted nut wrench

▪ Remove hub, page 42

Load carrying fixture

▪ Remove hub, page 42

▪ Dismantling hub, page 44

Figure Order no. Quantit Comment

▪ Remove left portal drive, page 48

▪ Dismantling left portal drive,