REAR AXLE -12

Contents

TRAVELLING - D

REAR AXLE -12.A

TECHNICAL DATA REAR AXLE

General specification .................................................................................................................................... 3

Torque .......................................................................................................................................................... 3

Special tools ................................................................................................................................................. 5

Final drive General specification .................................................................................................................................... 7

FUNCTIONAL DATA REAR AXLE

Sectional view .............................................................................................................................................. 8

Static description ........................................................................................................................................ 10

SERVICE REAR AXLE

Remove ...................................................................................................................................................... 11

Install .......................................................................................................................................................... 15

Adjust .................................................................................................................................................. 19

Final drive Remove ...................................................................................................................................................... 26

Install .......................................................................................................................................................... 30

Shaft - Remove .......................................................................................................................................... 34

Shaft - Install .............................................................................................................................................. 36

Reducer, spur gear - Overhaul .................................................................................................................. 38

Differential Overhaul..................................................................................................................................................... 40

Differential lock Overhaul..................................................................................................................................................... 44

Housing Overhaul..................................................................................................................................................... 49

DIAGNOSTIC REAR AXLE

Troubleshooting.......................................................................................................................................... 63

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TRAVELLING - REAR AXLE

REAR AXLE - General specification

Pinion and crown wheel ratio: Puma CVT Models 165 180 195 210 225 Pinion to crown wheel backlash

Teeth I Ratio

mm

9 I 47 = 1:5.222

0. 25 to 0. 33 Epyciclic reduction Ratio 12 / 27 / 69 : 1 6.750 Differential 4-pinion Differential lock control: - Multi-plate clutch

Acting through a hydraulically

controlled multi-pack clutch in oil bath Number of clutch discs: - Driven discs. Quantity 4 - Drive discs. Quantity 4 - Driven disc thickness (each) mm 3. 45 to 3. 55 - Drive disc thickness (each) mm 1. 95 to 2. 05 Differential pinion bore dia. (Refer mm 30. 04 to 30. 061 to REAR AXLE - Sectional view

(D.12.A))

Differential pinion journal dia. }} 29. 939 to 29. 960 Differential pinion runninq clearance }} 0. 080 to 0. 122 Side gear hub seat in differential Casing dia. (Refer to REAR AXLE - mm 70. 0 Sectional view (D.12.A))

Side qear hub dia. }} 68. 0

Pinion shaft position adjustment (Refer to REAR AXLE - Sectional view (D.12.A)) - shims available

mm

Refer to REAR AXLE - Adjust (D.12.A)

3. 0-3. 1-3.2-3.3-3.4-3.5-3.6

3.7-3.8-3.9-4.0 Pinion bearing adjustment Refer to REAR AXLE - Adjust

(D.12.A) Pinion bearing shimming (Refer mm 4. 40-4. 50-4. 60-4. 70-4. 80-4. to REAR AXLE - Sectional view 85-4. 90-4. 95-5. 00-5. 05-5. 10-5. (D.12.A)) 15-5. 20-5. 25-5. 30-5. 35-5. 40-5.

45-5. 50-5. 55-5. 60-5. 65-5. 70-5. 75-5. 80-5. 85-5. 90-5. 95-6. 00-6. 05-6. 10-6. 15-6. 20-6. 30-6. 40-6. 50-6. 60

Crown wheel bearing and backlash

shims available (Refer to REAR AXLE - Adiust (D.12.A))

mm

Refer to REAR AXLE - Adjust (D.12.A)

0. 15-0. 20-0. 50

Differential gear and pinion backlash mm 0. 20 Differential gear thrust washer

thickness

(Refer to REAR AXLE - Adjust mm 2.70-2.75-2.80-2.85-2.90 (D.12.A) and REAR AXLE - 2.95-3.00-3.05-3.10-3.153. 20-3. Sectional view (D.12.A)) 25-3. 30 Differential gear end play (each) mm 0. 226 +/-0.302 Differential gear end play adjustment Refer to Differential - Overhaul

(D.12.A)

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REAR AXLE - Torque

DESCRIPTION Thread size Torque Nm lb/ft

Nut, bevel pinion shaft M45 x 1. 5 500 369 Nut final drive case M14x1.5 200 148 Nut wheel disc to wheel rim M16 x 1.5 250 184 Nut, steel wheel disc to wheel hub

M18 X 1.5 255 188

Capscrew, wheel hub on dual wheel axle shaft

M16 x 1.5 294 217

Capscrew, RAIL disc on dual wheel axle shaft

M16 x 1.5 294 217

Capscrew, drive wheel shaft M18 x 1.5 88 (*) 65 (*) Capscrew, crown wheel and differential caps

M10 x 1.25 54 40

Capscrew, crown wheel M14 x 1.5 195 144 Nut RAIL disc block M20 x 2.5 245 181 Nut RAIL disc to wheel hub M18 X 1.5 314 232 Nut, weight screw to steel wheel disc

M16 x 1.5 294 217

Attaching screws, wheel weiqhts

M16 X 1.5 211 156

Allen screw, wheel weights to cast iron disc

M16 X 1.5 186 137

(*) see adjustment procedure, for further information, refer to Final drive Shaft - Install (D.12.A)

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BA!L08CVT3(32HVA


BAIL08CVT362HVA 1

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REAR AXLE - Special tools

CAUTION The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

List of special tools necessary to carry out the different operations described in this Section. 380000301 Rotary stand 380000272 Front bracket for rear axle overhaul (to be used with

380000301) 380000273 Rear bracket for rear axle overhaul (to be used with

380000301)

B008

X 380000459 380001783 X 380000470 X 380200088

380000249 X 380200104 380000240 X 380000475 380000462 380000549 X 380000486 MS2700C

Nut wrench for checking pinion rolling torque Transfer box shaft puller Pinion bearing adjustment tool Pinion bearing adjustment tool extension (to be used with 380000470 Universal pinion installer Crown wheel-differential lifting tool Universal differential lock pressure test kit Differential planetary gear adjustment tool Differential overhaul stand. Slide hammer. Spacer and bushing (to be used with 380000470 ). Tractor splitting kit

Tool to be fabricated to disassemble-assemble the Bevel Pinion Shaft

• Make from 60 mm socket (remove square drive end). • Weld suitable rectangular piece of metal to socket (See Fig. 1). • Use in conjunction with pinion drive coupler and 3/4 in drive socket. (Refer to Housing - Overhaul (D.12.A)).

60mm

T 150mm

1

1b0o2004105982 1

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Final drive - General specification

Type Epicyclic, with three planetary spur gears Reduction ratios: Puma CVT 69 / 12 = 1.675 to 1 Models 176 180 195 210

Puma CVT Model 225 Thickness of planetary gear thrust washers (Refer to REAR AXLE - Sectional view (D.12.A) ) Thickness of planetary gear roller bearing spacer (Refer to REAR AXLE - Sectional view (D.12.A))

mm }}

Epicyclic, with four planetary spur gears

1 4.90 to 4.95

Adjustment of drive wheel shaft tapered roller bearinqs

Refer to Final drive Shaft - Install (D.12.A)

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REAR AXLE - Sectional view

BAIL08CVT363FVA

1 Bevel pinion shaft

BAIL08CVT363FVA 1

Rear Axle Longitudinal Sectional View

2 Tapered roller bearing 3 Bevel pinion bearing adjusting shim 5 PTO Drive Shaft 7 Crown Wheel 9 Differential gear 11 Four Wheel Drive Clutch

4 Hydrostat input speed sensor 6 PTO Clutch 8 Differential gear hub 10 Pinion shaft position shim

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BAIL08CVT364FVA

BAIL08CVT364FVA 2

Rear Axle Cross-Section (with multi-plate clutch differential lock)

1 Seal 3 Planetary final reduction gears 5 Planetary gear bearing spacer 7 Bearing cap support 9 Differential pinion 11 Side gears 13 Bearing cap support 15 Seal 17 Driven discs 19 Inner and outer seals 21 Output shaft

2 Differential output half shaft 4 Thrust washer 6 Thrust washer 8 Planetary carrier 10 Differential gear hub 12 Differential lock control piston 14 Output shaft 16 Drive discs 18 Crown Wheel Guard 20 Side Gear End Play Adjuster Rings 22 Planetary reduction gear carrier

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REAR AXLE - Static description The rear axle assembly transfers drive from the transmission to the epicyclic final drives through a bevel pinion and crown wheel coupling. The bevel gears are spiral type and are supported by tapered roller bearings. The differential is fitted with four planetary gears and hydraulic differential lock, the differential lock being of a multi- plate type. The epicyclic final reduction gear sets are controlled by the bevel pinion and hypoid crown wheel and output the drive through the final drive-shafts.

1 Pinion Nut 3 Four Wheel Drive Gear 5 Sensing Gear 7 Piston 9 Bolt 11 Lock Plate 13 Shaft and Bevel Pinion 15 Spacer 17 Shim

BSD2313A 1

Crown Wheel and Pinion Components

2 Bearing 4 Parking Brake Disc Hub 6 Crown Wheel 8 Cover 10 Driven Disc 12 Differential Casing 14 Bearing 16 Brake Discs

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BSD2313A


REAR AXLE - Remove Prior operation: Disconnect the rear axle from the transmission housing, for further information refer to Housing - Disconnect (C.20.G)

DANGER

Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Make sure that units or parts are supported by suitable slings or hooks. Make sure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death.

1. Remove the transmission housing drain plug and drain the transmission oil into a suitable container. Install the drain plug and tighten to 68 - 82 Nm ( 50 - 60 lbft).

2. Remove top lift arm.

3. Remove the electronic draft control (EDC) sensor retaining bolts.

NOTE: Repeat this step for the right-hand side.

B012

BAIL08CVT256AVA 1

BAIL08CVT169AVA 2

BAIL07APH394AVA 3

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4. Remove the lift link lower retaining pin and slide out the hinge pin.


5. Remove the hinge pin with the EDC sensor and remove the lower lift arm.


6. Remove the retaining bolt (1), remove the hinge pin (2) and remove the lift link (3).


Vehicles with extending drawbar7. Remove the split pin (1) and remove the lift rod lower

retaining pin (2).


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BAIL07APH395AVA 5

BAIL07APH398AVA 6

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9. Disconnect the extending drawbar hydraulic supply and return pipes.

10. Unlatch the extending drawbar (1) and lower on a suitable jack (2).

11. Remove the extending drawbar retaining bolts.

BAIL08CVT015AVA 8

BAIL07APH399AVA 9

BAIL08CVT174AVA 10

BAIL08CVT175AVA

BAIL08CVT175AVA 11

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8. Remove the retaining bolt, and remove the extending drawbar lift rod.



13. Remove the extending drawbar retaining bolts.

14. Remove the extending drawbar assembly.

BAIL08CVT174AVB 12

BAIL08CVT176AVA 13

BAIL08CVT177AVA 14

Next operation: Remove the rear PTO, for further information refer to Housing - Remove (C.40.C) Next operation: Remove the stack valve, for further information refer to Stack valve - Remove (A.10.C) Next operation: Remove the final drive housing, for further information refer to Final drive - Remove (D.12.A)

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12. Raise the extending drawbar assembly (1) and re- latch the extending drawbar (2).


REAR AXLE - Install Prior operation: Install the final drive housing, for further information refer to Final drive - Install (D.12.A) Prior operation: Install the stack valve, for further information refer to Stack valve - Install (A.10.C) Prior operation: Install the rear PTO, for further information refer to Housing - Install (C.40.C)

DANGER


B012

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS.

B020

Vehicles with extending drawbar 1. Install the extending drawbar assembly.

BAIL0BCVT177AVB 1

2. Install the extending drawbar retaining bolts. Tighten to 211 Nm (155 lb ft).

BAIL08CVT176AVA 2

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BAIL08CVT177 AVB e

BAIL08CVT176AVA

3. Unlatch the extending drawbar (1) and lower on a suitable jack (2).

BAIL08CVT174AVA 3 •-


4. Install the extending drawbar retaining bolts. Tighten to 211 Nm (155 lb ft).

5. Raise the extending drawbar assembly (1) and re- latch the extending drawbar (2).

6. Connect the extending drawbar hydraulic supply and return pipes.

BAIL08CVT175AVA 4

BAIL0BCVT174AVB 5

BAIL07APH399AVA 6

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7. Install the extending drawbar lift rod and install the retaining bolt.



BAIL08CVT015AVA 7

8. Install the lower retaining pin (1) and install the split pin (2).


BAIL07APH396AVB 8

All vehicles 9. Install the lift link (1), install the hinge pin (2) and

install the retaining bolt (3).


_

10. Install the hinge pin with the EDC sensor into the lift arm.


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11. Install the lift link lower hinge pin and install the retaining pin.


12. Install the EOG sensor retaining bolts.


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13. Install the top lift arm.

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BAIL08CVT169AVA 13

Next operation:Connect the rear axle to the transmission housing, for further information refer to Housing - Connect (C.20.G) Next operation:

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BAIL07APH394AVA


REAR AXLE - Adjust

BSE2389A_140 1

Rear axle adjustment procedures (A) - Pinion shaft pre-load shim. Adjusts the pre-load on the pinion shaft bearings and components. (B) - Pinion shaft position shim. Adjusts the position of the pinion relative to the crown wheel.

(C) and (F)) - Left and right hand crown wheel backlash and differential support bearing pre-load shims. Adjusts the horizontal position of the crown wheel relative to the pinion gear. This affects the backlash depending on which side the shims are fitted. Also affects the pre-load on the differential support bearings, affected by the total shims, (C+F). ( (D) and (E)- Left and right differential side gear shims. Adjusts pre-load on differential gear assembly.

NOTE: The pinion and differential should be set up in the following order:

1. (D and E) For further information refer to: Differential lock - Overhaul (D.12.A) 2. (B) 3. (A) 4. (C and F)

1. Determining pinion shaft position shim thickness (Shim (B) figure 1) using special tool number 380000470 with adaptor 380200088. Proceed as follows: Place pinion rear bearing outer cup into the rear axle housing less shim.

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2. Assemble special tool number 380000470 with extension adaptor 380200088 (1) complete with the bearings into the rear axle housing. Lock the nut while turning the bearings.

24395 2

3.

BSG6046A 3

4. Assemble universal tool number 380000249 (2) on

crown wheel caps (1) complete with the bearing outer

cups.

Bring the rod of tool number 380000249 (H) to con-

tact bearing inner cup and measure dimension (H1).

Determine correct nominal dimension, H2 (2) be-

tween the crown wheel centre line and pinion base: H2 = H3 ± C

where: H3 = 212 mm. Nominal dimension between the

crown wheel centre line and pinion base.

C = Correction factor stamped on the pinion, ex-

pressed in mm and prefixed by + or - if other than

0, to be added to or subtracted from the nominal di-

mension (H3), depending on the sign. BSE2619A 4

NOTE: The crownwheel is a hypoid type, whereby the pinion engages with the crownwheel 12 mm below centreline of the crownwheel. When taking measurement H1 in the previous step the measurement must be taken perfectly perpendicular to the bearing face.

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5. Adjuster shim thickness (S1) is given by: S1 = H1 - H2 where: H1 = Depth gauge reading

H2 = Correct nominal dimension between crown wheel centre line and pinion base. If necessary, round up the value (S1) to the next 0.05 mm. Examples: - Depth gauge reading: H1 = 215.4 mm - Nominal dimension between crown wheel centre line and pinion base: H3 = 212 mm Example 1: - Correction factor: C = + 0.1 mm - Correct nominal dimension: H2 = 212 + 0.1 = 212.1 mm - Adjuster shim thickness - S1 = 215.4 - 212.1 = 3.3 mm Example 2: - Correction factor: C = - 0.1 mm - Correct nominal dimension: H2 = 212 - 0.1 = 211.9 mm - Adjuster shim thickness: - S1 = 215.4 - 211.9 = 3.5 mm Example 3: - Correction factor C = 0 mm - Correct nominal dimension: H2 = H3 = 212 mm - S1 Adjuster shim thickness: - S1 = 215.4 - 212 = 3.4 mm

6. Remove universal tool number 380000249 . 7. Determining pinion shaft pre-load shim thickness

(Shim (A) figure 1) of the pinion shaft tapered roller bearings using special tool number 380000470 with extension adaptor 380200088. Proceed as follows: 1. Using a depth gauge, measure dimension (H6) between the end of tool number 380000470 (1) and the end of the inner screw. 2. Remove tool number 380000470. from the rear axle housing.

24397 5

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8. Fix tool number 380000470 into a vice, assemble all parts onto it including a test shim (P) . Screw in the tool nut to lock the tool and using a depth gauge measure dimension (H7) between the tool end and end of the inner screw. Adjuster shim thickness (S2) is given by: S2 = H6 + P + S1 - H7 +0.2 where: P = Test shim S1 = Pinion shaft position adjustment shim, as found in the previous paragraph. 0.2 mm = Increase necessary to compensate for bearing increased preload deriving from tightening of the pinion shaft locknut If necessary, round up the value (S2) to the next 0.05 mm

BAIL07APH633AVB 6

Example - Pinion shaft position adjustment shim, found in the previous paragraph: S1 = 1.8 mm - Depth gauge reading: H6 = 13.60 mm Test shim P = 2 mm Depth gauge reading H7 = 12.10 mm Adjuster shim thickness. S2 = 13.60+2+1.8-12.1+0.2 = 5.5 mm

9. Adjustment of crown wheel bearing pre-load and crown wheel to pinion backlash, shims (C+F), Figure 1

Proceed as follows: 1. Assemble the rear bearing outer cup (1) and shim (S1) as in previous adjustments ..

10. Assemble pinion (1) complete with all components and respective bearing adjuster shims as found dur- ing previous adjustments. If necessary, hold the pinion in place using a suitable tool.

NOTE: Pinion bearing shims are listed in REAR AXLE - General specification (D.12.A).

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if higher.

12. Assemble the crown wheel and differential assembly to the rear axle housing, insert the right-hand cap complete with a test shim and secure with three bolts. Tighten the bolts to 54 Nm (40 lb ft).

13. Measure left-hand cap thickness (01 ).

14. Assemble the left-hand cap without adjuster shims using three lubricated bolts (1) arranged at 120 °. Tighten alternatively and gradually the three bolts (1) to 6 - 9 Nm (4 - 7 lb ft) while turning the crown wheel to settle the bearings.

BAIL07APH657AVA 9

BSE2621A 10

BSE2620A 11

BSE2515A_143 12

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11. Using a suitable tool, hold the pinion nut steady. Using a suitable tool and 3/4 in drive socket, rotate the pinion counterclockwise to install the nut. Tighten the pinion nut to 500 Nm (369 lb ft), while turning the pinion shaft to settle the bearings. Re- move the pinion tool. Check if the rolling torque necessary to turn the pinion shaft is 1.0 - 2.0 Nm (0.7 - 1.5 lb ft) by measuring it at the end of the shaft using the suitable tool (1) and torque wrench tool number 380000506 Stake the new pinion nut.

NOTE: Decrease the bearing adjustment shim pack if the rolling torque is lower than specified, or increase it


15. Using a depth gauge, measure dimension (D) at the

two recesses in the left-hand cap. Calculate the average of the two readings. The total shim pack (S) to be inserted beneath the

right-hand and left-hand caps is given by:

S = D2-D1+A+0.3

where: A= Test shim= 1.5 mm D1 = left-hand cap thickness, in mm.

D2 = Dimension measured at 18, in mm.

0.3 mm= Increase necessary to diminish the bearing

preload deriving from the bolts.

If necessary, round up the value (S) to the next 0.05

mm. 24404 13

16. Using a dial gauge, measure the backlash (G) be-

tween the crown wheel and pinion teeth (take threemeasurements at 120 ° and take the average of the

readings). Normal crown wheel to pinion backlash is 0.20 - 0.28

mm, with an average of 0.24 mm

To compensate for possible backlash values higher

or lower than specified, consider the 1:1.34 ratio ex- isting between normal backlash and corresponding crown wheel end displacement. Therefore, the end displacement (Z) necessary to

restore specified backlash is: Z = (G - 0.24) x 1.34 Adjustment shim packs (Sd and Ss) to be inserted on the right-hand and left-hand caps are given by: 24405 14

Sd =AZ Ss = S - Sd where: S = Total shim pack value Z = Crown wheel end displacement, found above. A= Test shim= 1.5 mm

17. Assemble the shim packs determined above on the

caps and tighten the bolts to the specified torque.

18. Check if the rolling torque necessary to turn the crown wheel and pinion assembly is: Rp + ( 1.25 - 2.0 Nm (11.1 -17.7 lb in) by measuring it at the end of the pinion shaft using the wrench

tool number 380000459 (1) and torque wrench tool

number 380000506 (2). where: Rp = Rolling torque measured for the pinion only

Example:

- Measurement of left-hand cap thickness (D1) =

14.00 mm - Test shim A= 1.5 mm - Measurement of clearance of D2 between left-hand cap and its seat on the rear axle housing 14.15 mm; 14.25 mm.

24400

15

D2 = Mean value (14.15 + 14.25):2 = 14.20 mm

- Total adjuster shim thickness

S = 14.20-14.00 + 1.5 + 0.3 = 2.00 mm - Measured backlash: 0.13 mm; 0.12 mm; 0.14 mm G = Mean value= (0.13 + 0.12 + 0.14): 3 = 0.13 mm

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- End displacement (Z) necessary to restore specified backlash. Z = (0.13 - 0.24) X 1.34= - 0.11 X 1.34 = - 0.15 - Adjuster shim thickness to be inserted on the right- hand cap is: Sd = 1.5 - 0.15 = 1.35 mm - Adjuster shim thickness to be inserted on left-hand cap is: Ss = 2.00 - 135 = 0.65 mm

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Final drive - Remove Prior operation: Disconnect the battery , for further information refer to Battery - Disconnect (A.30.A) Prior operation: Vehicles with pneumatic trailer brakes, remove the relevant air tank, for further information refer to Air tank - Remove (A.20.A). Prior operation: Vehicles with pneumatic trailer brakes, remove the relief valve (if required), for further information refer to Relief valve - Remove (A.20.A).

WARNING


B012

NOTE: This procedure details removal of the left-hand final drive housing, removal for the right-hand is similar.

All Vehicles1. Remove the transmission housing drain plug and

drain the transmission oil into a suitable container. Install the drain plug and tighten to 68 - 82 Nm ( 50 - 60 lbft).

2. Raise and support the rear of the vehicle. Remove the left-hand rear wheel.

WARNING Tractor wheels are very heavy. Handle with care and ensure, when stored, that they cannot fall and cause injury. Never operate the tractor with a loose wheel rim or disc. Always tighten nuts to the specified torque and at the recommended intervals.

B105

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4. Raise and support the cab, for additional information refer to USER PLATFORM - Remove (E.34.A).

Vehicles with Cab Suspension 5. Disconnect the cab suspension check strap.

Remove the circlip (1) and remove the cab suspension check strap retaining pin (2).

BAIL07APH391AVA 3

6. Remove the right-hand side retaining nut and bolt from the panhard rod.

NOTE: This step is only necessary when removing the right-hand final drive housing.

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BAIL07APH280AVA 5

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3. Remove the lower arm sway limiter bracket.

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8. Remove the cab suspension damper.

9. Remove the cab damper mounting bracket.

Vehicles with Standard Cab 10. Remove the cab retaining nut.

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BAIL07APH408AVA 7

BAIL07APH409AVA 8

BAIL07APH367AVA 9

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7. Remove the cab support from the final drive housing.

11. Remove the cab support from the final drive housing.


BAIS06CCM123AVA 10

All Vehicles 12. Install special tools, lifting bracket 380001113 with

adaptor studs 380200096 and attach to suitable lifting equipment.

13. Remove the remaining final drive housing retaining nuts. Remove the final drive assembly together with the half shaft

BAIL08CVT320AVA 11

BAIL07APH411AVA 12

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Final drive - Install

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Make sure that units or parts are supported by suitable slings or hooks. Make sure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death.

B012

NOTE: This procedure details installation of the left-hand final drive housing, installation for the right-hand is similar.

All Vehicles 1. To aid installation of the housing install the drive

shaft.

2. Thoroughly clean the mating surfaces and apply a bead of sealant.

3. Install the final drive housing.

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4. Remove the special tools.

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Vehicles with Standard Cab 5. Install the cab support to the final drive housing.

Tighten to 300 Nm (221 lb ft).

6. Install the cab retaining nut. Tighten to 380 Nm (280 lb ft).

Vehicles with Cab Suspension 7. Install the cab damper mounting bracket.

BAIS06CCM123AVA 5

BAIL07APH367AVA 6

BAIL07APH409AVA 7

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9. Install the cab support to the final drive housing. Tighten to 300 Nm (221 lb ft).

10. Install the right-hand side retaining nut and bolt to the panhard rod. Tighten to 294 Nm (217 lb ft).

NOTE: This step is only necessary when installing the right-hand final drive housing.

All Vehicles 11. Install the lower arm sway limiter bracket.

BAIL07APH408AVA 8

BAIS06CCM123AVA 9

BAIL07APH280AVA 10

BAIL07APH391AVA 11

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8. Install the cab suspension damper. Tighten to 81 Nm (60 lb ft).

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12. Install the left-hand rear wheel. Tighten to 250 Nm (184 lb ft).

WARNING

Tractor wheels are very heavy. Handle with care and ensure, when stored, that they cannot fall and cause injury. Never operate the tractor with a loose wheel rim or disc. Always tighten nuts to the specified torque and at the recommended intervals. \

B105

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13. Fill the transmission with oil.

BAIL07APH363AVA 12

Next operation: Vehicles with pneumatic trailer brakes install the relief valve (if required), for further information refer to Relief valve - Install (A.20.A). Next operation: Vehicles with pneumatic trailer brakes install the relevant air tank, for further information refer to Air tank - Install (A.20.A). Next operation: Connect the battery, for further information, refer to Battery - Connect (A.30.A).

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Final drive Shaft - Remove Prior operation: Remove the final drive housing, for further information refer to Final drive - Remove (D.12.A)

WARNING

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

1. Position the final drive housing on a rotary stand.

2. Remove the locking plate (1) by slightly turning it if necessary.

3. Loosen the bolt attaching the planetary carrier (1) to the drive shaft.

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5. Remove the thrust washer.

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6. Using a suitable puller, remove the drive shaft.

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Next operation: Install the final drive shaft, for further information refer to Final drive Shaft - Install (D.12.A)

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4. Remove the planetary gear carrier.

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Final drive Shaft - Install Prior operation: Remove the final drive shaft, for further information refer to Final drive Shaft - Remove (D.12.A)

WARNING

Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. B020

1. Install the drive shaft into the final drive housing.

2. Install the thrust washer.

3. Install the planetary gear carrier.

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4. Turn the drive shaft by hand and check that it turns freely. Tighten the drive shaft bolt to 196 Nm (145 lb ft) while turning the drive shaft to settle the assembly. Loosen the drive shaft bolt and then tighten it again to 88 Nm (65 lb ft) while turning the drive shaft to settle the bearings correctly.

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6. Using the grease nipple, fill the inner recess with grease CASE AKCELA 251H EP MULTI-PURPOSE GREASE (several grease gun strokes are needed).

7. Remove the final drive housing from the rotary stand.

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Next operation: Install the final drive housing, for further information refer to Final drive - Install (D.12.A)

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5. Install the locking plate (1) and lock it by screwing the bolt in or out until reaching the next notch.

NOTE: Screw the bolt in or out to a maximum angular variation of 15 °.


Final drive Reducer, spur gear - OverhaulPrior operation: Remove the final drive shaft, for further information refer to Final drive Shaft - Remove (D.12.A)

WARNING


1. Remove the retaining ring.

2. Slide out the pivot pins and recover the gears complete with the needle bearings. Remove the thrust washer (1).

3. Check all components for wear. 4. Install a new thrust washer (1) on the driven gear

holder. Install new gears and needle bearings where necessary. Install the gears complete with the needle bearings and slide in the pivot pins.

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5. Install the retaining ring.


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Next operation: Install the final drive shaft, for further information refer to Final drive Shaft - Install (D.12.A)

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Differential - Overhaul

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

1. Remove the crown wheel retaining nuts and bolts.

2. Remove the differential housing from the crown wheel.

3. Remove the side gear (1) from the differential housing.

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5. Slide out the pivot pins (2) and recover the differential gears (1) from both sides.

NOTE: Keep the pivot pin and side gear matched as they are removed.

6. Withdraw the pivot pin (2), and recover the pivot pin holder (1) and side gears.

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7. Using a suitable puller, remove the differential housing bearing.

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4. Remove the locking pins (1) of the differential gear pivot pins.

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8. Using a suitable tool, install the differential housing bearing.

9. Side gear end float adjustment (Shims A and B Refer to REAR AXLE -Adjust (D.12.A) Assemble side gears, pivot pins and retaining pins.

10. Place the side gear (3) complete with a test shim (2) on tool number 380000475 (1)

NOTE: Adjust the left-hand side carrier end float as indicated for the right-hand side gear.

11. Assemble the side gear and attached tool number 380000475 on the differential casing, place the crown wheel above it and fix the crown wheel with three bolts (1). Turn the assembly to settle.

12. Place a dial test indicator gauge with the stylus on the tool screw (1), press the tool and set gauge to zero.

24415_530 8

24416_531 9

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13. Pull the tool (1) upwards and read the travel (H) on the gauge. Adjuster ring thickness to be inserted on the right- hand side gear is given by: Rd = (B + H) - 0,05 - 0.30 where: Rd = Adjustment shim to be inserted on the right- hand side gear. B = Test shim = 3.00 mm H = Travel measured using the gauge 0.05 mm = Half end play of differential gears in rela- tion to their pivot pins0.30 mm = Specified side gear end play.


24418 11

14. Example:- Travel measured using the gauge H = 0.50 mm - Test shim B = 3.00 mm- Thickness of the ring to be inserted on the right- hand side gear is Rd= (3.00 + 0.50) - 0.05 - 0.30 = 3.15 mm

15. Once determined the shim packs for the left-handand right-hand side gears, reassemble the whole unit.

16. Install the crown wheel retaining nuts and bolts and tighten to 137 Nm (101 lb ft).

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Differential lock - Overhaul

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

1. Using suitable feeler gauges, check the clearance

between the multi-wet plate clutch friction and steel discs. If the clearance is not between 1.35 - 3.1 mm (0.05 - 0.12 in), install new multi-wet plate clutch friction and steel discs.

2. Remove the crown wheel retaining nuts and bolts.

3. Remove the differential housing from the crown wheel.

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4. Remove the differential lock piston.

5. Remove the crown wheel by pushing the clutch housing downwards.

6. Remove the clutch discs.

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7. Remove the hub.

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9. Remove the differential lock piston oil seal.

10. Lubricate all components with CASE AKCELA HY-TRAN ULTRA oil.

11. Install the differential lock piston oil seal.

12. Using a suitable tool, install the clutch housing bearing.

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8. Using a suitable puller, remove the clutch housing bearing.

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14.

Install the clutch discs.

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15.

Install the crown wheel by pulling the clutch housing upwards.

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16. Install the differential lock piston.

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13. Install the hub.

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17. Install the differential housing to the crown wheel.


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18. Install the crown wheel retaining nuts and bolts and

tighten to 137 Nm (101 lb ft).

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Housing - Overhaul Prior operation: Remove the rear axle, for further information, refer to REAR AXLE - Remove (D.12.A). Prior operation: Remove the four-wheel drive clutch, for further information, refer to Clutch - Remove (D.14.C).

WARNING


1. Detach the return springs.

2. Remove the parking brake control assembly.

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Rear brakes 3. Remove the brake lubrication oil retention plates.

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5. Remove the rear brake retaining plate.

6. Remove the outer friction brake disc.

7. Remove the intermediate steel brake disc.

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4. Remove the ring gear.

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8. Remove the inner friction brake disc.

9. Remove the brake piston.

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Crown wheel NOTE: If only the crown wheel and NOT the pinion is to be removed the rear axle does not need to be disconnected from the transmission. 10. Using a suitable socket remove the PTO twist sensor.

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12. Remove the crown wheel baffle plate.

13. Locate special tool 380200104 under the crown wheel teeth (1) and lock in position (2).

14. Support the weight of the crown wheel with the special tool. Remove the crown wheel support cap retaining bolts.


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11. Remove the crown wheel baffle plate retaining bolt.

15. Install two of the retaining bolts into the blind holes and tighten until the support cap and shims are removed.


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16. Using the suitable support under the special tool, re-

move the crown wheel and differential assembly.

Pinion 17. Disconnect the hydraulic pipe.

18. Unstake the pinion retaining nut. Using a suitable tool lock the pinion nut.

NOTE: For further information, refer to REAR AXLE - Special tools (D.12.A).

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19. Install a suitable splined socket onto the pinion shaft.


20. Turn the pinion shaft clockwise to remove the pinion

nut.

21. Partially remove the pinion shaft.

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22. Remove the bearing.

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24. Remove the spacer.

25. Remove the 4WD clutch drive gear (1) and the park brake discs (2). Remove the pinion shaft.

26. Remove the splined brake disc carrier (1), spacer (2) and sensing gear (3).

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23. Remove the bearing adjustment shim.

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28. Using a suitable driver tool, remove the pinion rear bearing cup from the rear axle housing, and recover the adjustment shim (if equipped).

29. Using a suitable driver tool, remove the pinion front bearing cup from the rear axle housing, and recover the adjustment shim (if equipped).

Hydraulic pump idler gear 30. Remove the idler shaft bearing retaining circlip.

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27. Using a suitable hydraulic press, remove the pinion bearing.

31. Remove the drive gear retaining circlip.

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32. Using a slide hammer (1), drift out the shaft. Retrieve the bearing (2), and drive gear (3).

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PTO shaft 33. Remove the PTO shaft bearing carrier.

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34. Remove the hydraulic pump drive gear and PTO bearing.

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36. Remove the circlip from the PTO shaft.

37. Install the pinion and bearing cups, carry out the procedures and adjustments as detailed in: REAR AXLE -Adjust (D.12.A).

38. Install the crown wheel and differential assembly, carry out the procedures adjustments as detailed in: REAR AXLE -Adjust (D.12.A).

39. Install the brake piston.

IMPORTANT: Make sure the notch on the piston is at the top of the housing

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35. Remove the circlip (1) remove the PTO shaft (2) remove the gear (3).

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40. When the piston is installed, the me1a)suredmthent (Xt) between the outer face of the piston ( an e ma -ing surface of the rear brake retaining plate (2) must read a minimum of 43.5 mm.


41. Install the inner friction disc.

42. Install the intermediate steel brake disc.

43. Install the outer brake friction disc.

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45.


44. Install the rear brake retaI·ni·ng plate.

hly clean and degrease the mating surfaces and apply ab ead of sealant.

46. Install the r·ing gear.

47_ Install the brake lubrication oil retention plates.

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48. Before installing the parking brake control assembly unit to the rear axle housing, thoroughly clean and degrease mating surfaces and apply a bead ofsealant approximately 2 mm of diameter following pattern shown.

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS.

B020

49. Using special tool 380200014, align the brake discson the pinion shaft.

50. Install the special tool 380200014, between the friction pads.

51. Position the parking brake control assembly complete with the special tool 380200014, between the brake discs on the pinion shaft. Remove the special tool while installing the parking brake control assembly.

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53. Attach the return springs.

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Next operation: Install the four-wheel drive clutch, for further information, refer to Clutch - Install (D.14.C). Next operation: Install the rear axle, for further information, refer to REAR AXLE - Install (D.12.A).

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52. Tighten the parking brake control assembly retaining bolts to 49 Nm ( 36 lb ft).

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REAR AXLE - Troubleshooting

Problem Possible Cause Correction Noisy rear axle when the vehicle is moving, and also with the transmission in neutral (not originating from final drives)

Pinion and/or crown wheel bearing incor- rect adjustment

Remove the rear axle housing and adjust the pinion and crown wheel bearings correctly

Excessive wear or incorrectly adjusted sun and planetary gears

Remove the differential, install new parts where necessary and adjust the differential lqear backlash

Excess differential side gears to half-shaft spline backlash

Remove the differential, install new parts where necessary and adjust the differential lqear backlash

Noisy rear axle with the vehicle under load and upon release

Excessive pinion to crown wheel backlash Remove the rear axle housing and adjust the pinion and crown wheel bearings correctly

Defective internal rear axle component(s) Remove the rear axle housing, install new parts where necessary and adjust the differential gear backlash

Noisy rear axle and overheating

Low rear axle oil level Top up to the correct level

Insufficient backlash

pinion and/or crown wheel Remove the rear axle housing and adjust the pinion and crown wheel bearings correctly

Noisy final drive(s) when the vehicle is moving and also with the transmission in neutral

Final drive shaft bearing incorrectly adjusted

Remove the final drive housing and adjust the bearing(s)

Defective internal final drive component(s) Remove the final drive housing and install new parts where necessary

Excess final drive shaft to final drive spline backlash

Remove the final drive housing and install new parts where necessary

Differential lock not engaging.

Low rear axle oil level Top up to the correct level

Blocked oil filter Install a new oil filter Defective hydraulic pump Overhaul or install a new hydraulic pump Faulty differential lock switch Install a new switch Power supply not reaching the solenoid valve: detached or damaged connectors, defective solenoid valve or remote switch

Repair the electrical connection. Overhaul or install a new solenoid valve or remote switch

Differential lock control solenoid valve stuck on discharge

Overhaul or install a new solenoid valve

Oil leaks through the seals with consequent pressure drop: cylinder piston oil supply line seal(s)

Install new seal(s) where necessary

Differential lock not disengaging

Faulty differential lock/unlock switch Install a new switch

Power supply not reaching the solenoid valve: detached or damaged connectors, defective solenoid valve or remote switch

Repair the electrical connection. Overhaul or install a new solenoid valve or remote switch

Differential lock control solenoid valve stuck on delivery.

Overhaul or install a new solenoid valve

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Problem Possible Cause Correction With the differential lock engaged and the control switch on automatic mode, the differential lock does not disengage when raising the lift arms using the Fast Raise switch.

Faulty differential lock switch (connected to the Fast Raise switch).

Install a new differential lock switch.

With differential lock engaged, the differential lock does not disengage when the brake pedals are pressed.

Faulty differential lock switch (connected to the brake pressure switches/brake pedal switches).

Install a new differential lock switch.

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Index

TRAVELLING - D

REAR AXLE -12.A

Differential - Overhaul ............................................................................................................................................... 40

Differential lock - Overhaul........................................................................................................................................ 44

Final drive - General specification ............................................................................................................................... 7

Final drive- Install ..................................................................................................................................................... 30 Final drive - Remove ................................................................................................................................................. 26 Final drive Reducer, spur gear - Overhaul ................................................................................................................ 38

Final drive Shaft - Install ........................................................................................................................................... 36 Final drive Shaft - Remove........................................................................................................................................ 34

Housing - Overhaul ................................................................................................................................................... 49 REAR AXLE - Adjust ................................................................................................................................................. 19

REAR AXLE - General specification ........................................................................................................................... 3

REAR AXLE - Install............................................................................................................................ 15 REAR AXLE - Remove ............................................................................................................................................. 11

REAR AXLE - Sectional view ..................................................................................................................................... 8

REAR AXLE - Special tools ........................................................................................................................................ 5

REAR AXLE - Static description ............................................................................................................................... 10 REAR AXLE - Torque ................................................................................................................................................. 3

REAR AXLE - Troubleshooting ............................................................................................................ 63

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Documents

REAR AXLE -12