Repair Instructions

Repair Instructions
MT‑L 3085 II, MT‑L 3095 II

DHL‑2400, DL‑2400, D‑2400
DHL‑2700, DZ‑2700, D‑2700
Construction Equipment
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 ....................................................................................................................... 6
1.1 Document overview .......................................................................................................................... 6
2 Safety ......................................................................................................................... 7
2.1 Signal words and symbols .............................................................................................................. 7
2.2 General safety instructions .............................................................................................................. 8
3 Notes on Repair 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
3.9 After Repair Work .............................................................................................................................. 12
3.9.1 Run-in behavior for slide ring seals ............................................................................................... 12
4 Technical Data ............................................................................................................ 14

4.1 Oil ........................................................................................................................................................... 14
4.1.1 Oil grade .............................................................................................................................................. 14
4.2 Type plate ............................................................................................................................................. 14
5 Settings ...................................................................................................................... 15
6 Tightening Torques ..................................................................................................... 16
7 Workshop Equipment ................................................................................................. 18

7.1 Special tools ........................................................................................................................................ 18
7.2 Standard tools and fixtures ............................................................................................................. 31
7.3 Operating supplies and auxiliary materials ................................................................................. 36
8 Preparatory Activities .................................................................................................. 37

8.1 Mounting axle on assembly truck ................................................................................................. 37
8.2 Draining oil .......................................................................................................................................... 38
9 Replacing Components ............................................................................................... 39

9.1 Exchanging brake disks ................................................................................................................... 39
9.1.1 Removing brake disks ....................................................................................................................... 39
9.1.2 Installing the brake disks ................................................................................................................. 41
10 Dismantling ................................................................................................................ 44
10.1 Removing and disassembling output and brake ....................................................................... 44
10.1.1 Removing output ............................................................................................................................... 44
10.1.2 Dismantling output for variant with combined seal ................................................................. 45
EN 4474.751.113 - 2020-10 3
Table of Contents
10.1.3 Dismantling output for variant with slide ring seal ................................................................... 51
10.2 Dismantling axle housing, input and differential for variant with DHL/DL/D-2400 .......... 57
10.2.1 Removing and dismantling axle housing .................................................................................... 57
10.2.2 Dismantling input .............................................................................................................................. 59
10.2.3 Dismantling multi-disk differential lock DHL‑2400 ................................................................... 62
10.2.4 Dismantling multi-disk differential lock DL‑2400 ...................................................................... 66
10.2.5 Dismantling differential D‑2400 ..................................................................................................... 69
10.3 Dismantling axle housing, input and differential for variant with DHL/DZ/D-2700 ......... 73
10.3.1 Removing and dismantling axle housing .................................................................................... 73
10.3.2 Dismantling input .............................................................................................................................. 75
10.3.3 Dismantling multi-disk differential lock DHL‑2700 ................................................................... 78
10.3.4 Dismantling differential DZ‑2700 .................................................................................................. 83
10.3.5 Dismantling differential D‑2700 ..................................................................................................... 87
11 Testing, Measuring, Adjusting ..................................................................................... 92

11.1 Shim tables for variant with DHL/DL/D-2400 ............................................................................. 92
11.1.1 Shim tables .......................................................................................................................................... 92
11.2 Shim tables for variant with DHL/DZ/D-2700 ............................................................................ 93
11.2.1 Shim tables .......................................................................................................................................... 93
11.3 Checking contact pattern (Gleason‑gearing) ............................................................................. 96
11.3.1 Contact pattern on crown wheel shifted towards the root ..................................................... 97
11.3.2 Contact pattern on crown wheel shifted towards the tip ....................................................... 97
11.3.3 Special case "Line" contact pattern .............................................................................................. 98
11.4 Selecting the cover for adjusting the output shaft bearing .................................................... 98
11.5 Backlash ............................................................................................................................................... 99
12 Assembly .................................................................................................................... 100

12.1 Assembling differential, input and axle housing for variant with DHL/DL/D-2400 .......... 100
12.1.1 Assembling multi-disk differential lock DHL-2400 .................................................................... 100
12.1.2 Assembling multi-disk differential lock DL-2400 ....................................................................... 107
12.1.3 Assembling differential D-2400 ..................................................................................................... 112
12.1.4 Assembling input ............................................................................................................................... 116
12.1.5 Assembling and attaching axle housing ..................................................................................... 127
12.2 Assembling differential, input and axle housing for variant with DHL/DZ/D-2700 .......... 130
12.2.1 Assembling the multi-disk differential lock DHL-2700 ............................................................. 130
12.2.2 Assembling differential DZ‑2700 .................................................................................................. 137
12.2.3 Assembling differential D‑2700 ..................................................................................................... 141
12.2.4 Assembling input ............................................................................................................................... 145
12.2.5 Assembling and attaching axle housing ..................................................................................... 156
12.3 Assembling and installing output and brake .............................................................................. 159
12.3.1 Assembling output for variant with combined seal .................................................................. 159
12.3.2 Assembling output for variant with slide ring seal .................................................................... 169
12.3.3 Mounting output ................................................................................................................................ 179
12.4 Checking proper function of differential lock ............................................................................. 184
13 Follow-up Activities .................................................................................................... 186
4 EN 4474.751.113 - 2020-10
Table of Contents
13.1 Checking axle for leak tightness .................................................................................................... 186

13.2 Filling oil ............................................................................................................................................... 187
14 Annex ......................................................................................................................... 188

14.1 Formulary and conversion tables .................................................................................................. 188
14.1.1 Conversion of length units ............................................................................................................... 188
14.1.2 Conversion of mass units ................................................................................................................. 188
14.1.3 Conversion of force units ................................................................................................................. 189
14.1.4 Conversion of torque units .............................................................................................................. 189
14.1.5 Conversion of temperature units .................................................................................................... 190
14.2 Overview of revisions ........................................................................................................................ 190
EN 4474.751.113 - 2020-10 5
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 as they are a prerequisite for fault-free
operation of the product and for the warranty granted by ZF Friedrichshafen AG. Please get in touch with
your contact if you need binding documents.
Document no. Denomination Technical information

5871.529.902 Operating Instructions
Tab. 1
6 EN 4474.751.113 - 2020-10
Safety
2 Safety
2.1 Signal words and symbols
This document contains particularly highlighted safety instructions which are marked 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 4474.751.113 - 2020-10 7
Safety
2.2 General safety instructions
Read all safety instructions and information. Failure to comply with safety instructions and information 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 the
time of 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. The ZF product in its
delivery status is safe to operate. However, the ZF product may pose dangers if improperly used by
unauthorized, untrained and uninstructed staff or if not used according to its intended use.
Figures might deviate from the ZF product and are not drawn to scale. No conclusions can be drawn with
regard to size and weight.
Installation, commissioning, maintenance and repair

Perform assembly, commissioning, maintenance and repair work exclusively according to this
documentation and other applicable documents.
Observe the following points:

• Employ authorized, trained and instructed staff.
• Observe technical provisions.
• Only use genuine ZF spare parts.
• Only use genuine ZF accessories.
• Only use genuine ZF special tools.
• Unauthorized changes and modifications lead to the expiry of the operator's license, warranty or
guarantee.
In case of damage, contact ZF and have the following information on the product ready:
• Type
• Parts list [BoM] number
• Serial number
• Operating hours
• Description of damage
Observe safety instructions, valid safety regulations and legal conditions to prevent malfunctions and
damage.
The country-specific safety regulations, accident prevention regulations and environmental protection
provisions apply additionally.
Wear safety-relevant workwear for all work. Depending on the work, also wear personal protective
equipment.
After completing the work, check correct function and functional security.
8 EN 4474.751.113 - 2020-10
Safety
Handling of ZF product
Unauthorized changes and modifications might impair functional security. Changes, modifications and
applications are only permissible upon written approval by ZF Friedrichshafen AG.
Observe the following when working on the ZF product:

• Secure workspace.
• Only carry out work at the unit when in a voltage-free state.
• Protect unit against being started accidentally. Attach instruction plate where it is clearly visible.
• Perform work when engine is switched off.
• Protect engine against being started accidentally. Attach instruction plate where it is clearly visible.
• Do not stand beneath a suspended load.
• Do not work on a suspended load.
• Only use permitted means of transport and lifting devices with sufficient load-bearing capacity.
• Close open tubings and hoses and avoid damage.
• Observe tightening torques.
• Protect cables against mechanical damage.
Noise
Noise might cause irreversible damage to hearing.
The perception of acoustic signals, warning calls or sounds warning of impending danger is impaired by
noise.
Observe the following when working on the ZF product:

• Avoid noise.
• Wear ear protection.
Operating supplies and aids

Operating supplies and aids might cause permanent damage to health and environmental damage.
Observe the following when selecting operating supplies and aids:

• Health risks
• Environmental compatibility
• Material safety data sheets
Observe the following when handling operating supplies and aids:

• Store operating supplies and aids in suitable and correctly labeled containers.
• Seek medical help in case of injuries due to hot, cold or caustic operating supplies or aids.
Observe the following to protect the environment:

• Collect leaking operating supplies and aids in sufficiently large containers.
• Observe disposal regulations.
• Observe material safety data sheets.
EN 4474.751.113 - 2020-10 9
Notes on Repair and Assembly
3 Notes on Repair 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. The ZF-Service Information is
available at all ZF Services Partner or in the ZF-ServiceLine.
• In case of doubt, always contact the relevant expert departments of ZF Aftermarket.
• 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 4474.751.113 - 2020-10
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.

• Clean lined clutch disks with a lint-free cloth only.
• Remove sealing compound residues on sealing faces or retaining agent residues, 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, preservatives 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 preservatives 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
EN 4474.751.113 - 2020-10 11
• Single-use parts
• 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
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 burrs caused by the disassembly of the ZF product
• Fretting corrosion
• Paint and corrosion damage
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 specialized staff. Remove burrs or other similar instances of unevenness.
3.9 After Repair Work
3.9.1 Run-in behavior for slide ring seals
The slide ring seals in the outputs require a running-in period of up to 100 operating hours. During this
time the characteristic contact pattern of the two halves of the seal ring develops.
During this time a leakage of a few drops is possible.
Requirements:
• A new slide ring seal is installed.
• Axle is installed into the vehicle.
Observe the environmental regulations (refer to section General safety instructions, page 8).
12 EN 4474.751.113 - 2020-10
1.
Damage to the slide ring seals is possible.

ð Maintain the specified driving speed.
During the first ten minutes while driving the vehicle do not exceed max. speed of 5 km/h.
2. After ten minutes driving time, check the outputs for possible oil leakage and wipe off any escaped
oil.
3. Continue driving and slowly increase the driving speed.
4. Subsequently, check the outputs for possible oil leakage again and wipe off any oil that may have
escaped.
Continue to increase the driving speed and prolong test cycles.
EN 4474.751.113 - 2020-10 13
Technical Data
4 Technical Data
4.1 Oil
4.1.1 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 05 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
2 Serial number
3 Number of List of Lubricants
4 Characteristics
5 Customer spec. number, if known to ZF
6 Parts list [BoM] number
The following data should be quoted when making inquiries

or undertaking repairs: 1, 2, 6
Fig. 1 Type plate
14 EN 4474.751.113 - 2020-10
Settings
5 Settings
Designation Dimensions Measuring Comment

instrument Chapter/Section
Check disk clearance of the 1.05 mm ±0.1 mm Depth gage • Assembling multi-disk differential lock
multi-disk differential lock DHL-2400, page 100
Determine disk clearance of 0.2 mm to 0.7 mm Depth gage • Assembling multi-disk differential lock
the multi-disk differential lock DL-2400, page 107
Rolling torque of pinion 1.5 Nm to 4 Nm Torque wrench • Assembling input, page 116
bearing with dial gage • Assembling input, page 145
Measure disk clearance of the 1.05 mm ±0.1 mm Depth gauge • Assembling the multi-disk differential
multi-disk differential lock lock DHL-2700, page 130
Thickness of disk package 19.80 mm to Depth gage • Assembling differential DZ‑2700,
20.00 mm page 137
Axial clearance of sun gear 0.5 mm to 2.0 mm • Mounting output, page 179
shaft
EN 4474.751.113 - 2020-10 15
Tightening Torques
6 Tightening Torques
Designation Tightening torque Measuring Comment

Locking screw M16 x 1.5 400 Nm Torque wrench • Assembling multi-disk differential lock
DHL-2400, page 100
• Assembling multi-disk differential lock
DL-2400, page 107
• Assembling differential D-2400,
page 112
• Assembling the multi-disk differential
lock DHL-2700, page 130
• Assembling differential DZ‑2700,
page 137
• Assembling differential D‑2700,
page 141
Hexagon screw M14 - 10.9 185 Nm Torque wrench • Assembling multi-disk differential lock
DHL-2400, page 100
page 112
Slotted nut M50 x 1.5 1,200 Nm Torque wrench • Assembling input, page 116
• Assembling input, page 145
Hexagon screw M20 - 10.9 560 Nm Torque wrench • Assembling input, page 116
• Assembling and attaching axle
housing, page 127
housing, page 156
Screw plug M24 x 1.5 50 Nm Torque wrench • Assembling and attaching axle
housing, page 127
housing, page 156
Screw-in sleeve M18 x 1.5 36 Nm Torque wrench • Assembling and attaching axle
housing, page 127
housing, page 156
Hexagon nut M27 x 1.5 100 Nm Torque wrench • Assembling and attaching axle
housing, page 127
housing, page 156
Union nut 100 Nm Torque wrench • Assembling and attaching axle
housing, page 127
housing, page 156
Hexagon screw M8 - 10.9 34 Nm Torque wrench • Assembling output for variant with
combined seal, page 159
• Assembling output for variant with
slide ring seal, page 169
Locking screw M18 x 2 - 12.9 200 Nm Torque wrench Assembling aid to insert the planetary
carrier until contact is obtained.

16 EN 4474.751.113 - 2020-10
Tightening Torques
Designation Tightening torque Measuring Comment

Locking screw M18 x 2 - 12.9 200 Nm Torque wrench Initial torque

Locking screw M18 x 2 - 12.9 600 Nm Torque wrench • Assembling output for variant with
Hexagon screw M18 - 10.9 390 Nm Torque wrench • Mounting output, page 179
Breather valve 30 Nm Torque wrench • Mounting output, page 179
Screw plug oil drain axle drive 50 Nm Torque wrench • Checking axle for leak tightness,
housing M36 x 1.5 page 186
Oil drain screw plug axle 50 Nm Torque wrench • Checking axle for leak tightness,
housing M24 x 1,5 page 186
Screw plug M36 x 1.5 50 Nm Torque wrench • Checking axle for leak tightness,
page 186
EN 4474.751.113 - 2020-10 17
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. Qty. Comment

Designation
Chapter/Section
5870.350.125 1
Support
• Mounting axle on assembly truck,

page 37
5870.350.077 1 1 set = 2 units
Supporting bracket

page 37
housing, page 127
housing, page 156
5870.350.000 1
Assembly truck

page 37
• Removing brake disks, page 39
• Dismantling output for variant with
5870.350.075 2 1 set = 2 units
Clamping fixture

page 37
housing, page 127
housing, page 156
18 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
5870.350.113 1
Clamping bracket
• Removing brake disks, page 39

AA00.680.530 1
Locating device
• Installing the brake disks, page 41

AA01.395.095 1
Load carrying fixture
• Removing output, page 44

• Mounting output, page 179
5870.300.017 1
Extracting device

EN 4474.751.113 - 2020-10 19
Workshop Equipment

Designation
Chapter/Section
5870.204.076 1
Eye nut

• Assembling the multi-disk
differential lock DHL-2700,
page 130
5870.300.019 1 56 mm to 110 mm
Extracting device

5870.204.073 1
Eyebolt

5873.014.016 1 To be used only in
connection with basic
Rapid grip device.

20 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
5873.004.001 1 Use only in connection
with gripping device.
Basic device
M150 x 3, length of sleeve
• Dismantling output for variant with 175 mm
AA01.061.332 2 M18 x 1.5
Load ring

5870.400.001 2
Offset screwdriver

• Dismantling input, page 59
5873.014.013 1 To be used only in

Rapid grip device.

EN 4474.751.113 - 2020-10 21
Workshop Equipment

Designation
Chapter/Section
5870.281.083 1
Load-lifting equipment

5870.401.139 1
Slotted nut wrench

5870.240.002 1
Locking mechanism

AA00.338.279 2
Clamp

AA00.684.425 1 To be used only in

Gripping device device.

22 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
Basic tool
• Dismantling input, page 59 250 mm
AA01.195.394 1
Gripping device
• Dismantling multi-disk differential

lock DHL‑2400, page 62
• Dismantling differential DZ‑2700,
page 83
• Dismantling differential D‑2700,
page 87

Basic tool
• Dismantling multi-disk differential 125 mm
lock DL‑2400, page 66
page 69
page 83
page 87
5873.003.029 1
Gripping device

EN 4474.751.113 - 2020-10 23
Workshop Equipment

Designation
Chapter/Section
5873.003.011 1
Reduction

5870.100.075 1
Pressure piece

• Assembling multi-disk differential
page 130
5873.012.016 1 M95 x 2
Rapid grip

lock DL‑2400, page 66
page 69
AA02.233.363 1 M125 x 3
Rapid grip

24 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
Basic device
• Dismantling multi-disk differential 150 mm
5870.100.074 1
Assembly fixture

AA02.623.325 1 Ø 56 mm to 70 mm
Load-lifting equipment

page 83
page 87
page 137
page 141
5870.204.040 1 1 set = 2 units
Fixing pin M16 x 1.5 x 70

lock DL-2400, page 107
page 112
page 130
page 137
page 141
EN 4474.751.113 - 2020-10 25
Workshop Equipment

Designation
Chapter/Section
5870.100.069 1
Assembly fixture

page 130
5870.700.004 1 Measuring range

1 to 60 kN
Load cell

page 130
AA00.331.446 1
Lifting device

5870.200.022 1 580 mm
Straightedge

lock DL-2400, page 107
5870.058.079 1
Driver tool

26 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
5870.260.004 1 Length 230 mm
Handle

5870.345.080 1
Assembly fixture

AA00.848.434 1
Measuring disk

AA00.848.397 1
Measuring disk

AA00.860.154 2
Measuring support

EN 4474.751.113 - 2020-10 27
Workshop Equipment

Designation
Chapter/Section
5870.204.024 1 1 set = 2 units
Fixing pin M20 x 120

housing, page 127
housing, page 156
AA01.364.201 1
Test device

AA02.039.663 1
Screw coupling

• Checking proper function of
differential lock, page 184
5870.286.079 1 0‑1 bar
Fitting

• Checking proper function of
differential lock, page 184
• Checking axle for leak tightness,
page 186
AA02.052.369 1
Driver tool

28 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
with assembly device.
Insert
M22 x 1.5

with insert.
Assembly fixture

5870.506.172 1
Thrust collar

5870.051.065 1
Driver tool

AA00.360.730 1
Measuring disk

EN 4474.751.113 - 2020-10 29
Workshop Equipment

Designation
Chapter/Section
AA01.238.317 1
Pressure ring

5870.204.029 1 1 set = 2 units
Fixing pin M18 x 1.5 x 105
5870.287.007 1
High pressure pump
0501.207.939 1 M10 x 1
Clutch
5870.950.161 1 External thread M18 x 1.5

and internal thread 10 x 1
Reduction
30 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
Chapter/Section
5870.286.072 1
Bottle
AA02.576.273 1
Connection
• Checking axle for leak tightness,

page 186
7.2 Standard tools and fixtures
To repair this ZF product use the following standard tools and fixtures.
Standard tools:
Figure 2 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 800 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
EN 4474.751.113 - 2020-10 31
Workshop Equipment

Designation
5870.900.013 Contains the sizes:
Set of internal pliers I1, I2, I3, I4
Fig. 3
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 Span 80 mm
Two-armed extractor Throat depth 100 mm
5870.970.002 Span 120 mm
5870.970.003 Span 170 mm
5870.970.004 Span 200 mm
Fig. 7 5870.970.006 Span 350 mm
5870.970.007 Span 520 mm
Two-armed extractor Throat depth 300 mm to 500 mm
5870.970.026 Span 250 mm
5870.970.028 Span 380 mm
32 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
5870.971.002 Span 130 mm
Three-armed extractor Throat depth 105 mm
5870.971.003 Span 230 mm
5870.971.004 Span 295 mm
5870.971.005 Span 390 mm
Fig. 8 5870.971.006 Span 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
5870.221.500 230 V
Hot-air blower
5870.221.501 115 V
Hot-air blower
Fig. 12
EN 4474.751.113 - 2020-10 33
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 gage
Fig. 17
34 EN 4474.751.113 - 2020-10
Workshop Equipment

Designation
5870.200.066 Consisting of two pieces
Set of parallel gage blocks Height 70 mm
5870.200.067 Consisting of two pieces
Set of parallel gage blocks Height 100 mm
Fig. 18
5870.200.109 Length 150 mm
Digital caliper gage
Fig. 19
5870.200.072 Length 200 mm
Digital depth gage
5870.200.114 Length 300 mm
Digital depth gage
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
EN 4474.751.113 - 2020-10 35
Workshop Equipment
7.3 Operating supplies and auxiliary materials
Order no. Manufacturer name Comment

Designation Chapter/Section
0666.690.191 PHÖNIX SPIRITUS • Assembling input, page 116
Spirit • Assembling input, page 145
• Assembling output for variant with combined
seal, page 159
• Assembling output for variant with slide ring
seal, page 169
0666.690.022 LOCTITE 262 • Assembling input, page 116
Jointing compound • Assembling input, page 145
0666.690.044 LOCTITE 415 • Assembling output for variant with combined
Adhesive seal, page 159
seal, page 169
0671.090.428 WEICON® ANTI‑SEIZE AS 30 g
Mounting paste
• Assembling output for variant with combined
seal, page 159
seal, page 169
36 EN 4474.751.113 - 2020-10
Preparatory Activities
8 Preparatory Activities
8.1 Mounting axle on assembly truck
Special tools:
• 5870.350.125 Support
• 5870.350.077 Supporting bracket
• 5870.350.000 Assembly truck
• 5870.350.075 Clamping fixture
1.
Risk of injury due to uncontrolled motion of

the load.
Death or serious injury possible.
ð Only use the suspension points intended
for transportation purposes.
ð Only use secure, permitted, and tested
means of transport, chain hoist, and
lifting equipment with sufficient load
capacity and suitable lifting technology.
ð Ensure that lifting equipment such as
ropes and belts are not in contact with
sharp edges and are not knotted or Fig. 21
twisted.
ð Properly attach lifting appliances to load.
ð Observe the load's center of gravity! The
crane hook must be located above the
load's center of gravity.
ð Lift load slowly and observe whether the
load tilts or swivels out laterally. If
required, immediately put down load and
modify attachment.
ð Keep distance.
ð Do not walk under suspended loads.
ð Only ever move load under supervision.
Attach 5870.350.125 [Support] (3) and

5870.350.077 [Supporting bracket] (2) to
5870.350.000 [Assembly truck] (4).
2. Turn in 5870.350.125 [Support] (3) until

contact is obtained.
3. Put axle on 5870.350.077 [Supporting

bracket] (2) and fasten with four
5870.350.075 [Clamping fixture] (1).
EN 4474.751.113 - 2020-10 37
Preparatory Activities
4. Unscrew 5870.350.125 [Support] (3) until

contact with axle is obtained.
8.2 Draining oil
Observe the environmental regulations (refer to section General safety instructions, page 8).
1. Place suitable container under all the screw

plugs.
2. Loosen screw plug on axle drive housing and

drain oil.
Fig. 22
3. Loosen screw plugs on outputs and drain oil.
Fig. 23
38 EN 4474.751.113 - 2020-10
Replacing Components
9 Replacing Components
9.1 Exchanging brake disks
9.1.1 Removing brake disks
Requirements:
• Output is removed (refer to section Removing output, page 44).
Special tools:
• 5870.350.113 Clamping bracket
1.
Risk of crushing due to moving load.

Slight or moderate injury possible.
ð Move load slowly and carefully.
ð Do not reach into danger area!
Use 5870.350.113 [Clamping bracket] in

order to attach the output to the
5870.350.000 [Assembly truck].
Fig. 24
2. Remove retaining rings.
Fig. 25
EN 4474.751.113 - 2020-10 39
3. Pull off planetary gears.
Fig. 26
4. Remove end shim (1).
Fig. 27
5. Remove disk package (1).
Fig. 28
40 EN 4474.751.113 - 2020-10
9.1.2 Installing the brake disks
Special tools:
• AA00.680.530 Locating device
1.
Material damage due to jamming of parts

possible.
ð Press in part evenly.
Use the AA00.680.530 [Locating device] in

order to press the piston into the brake
housing until contact is obtained.
Fig. 29
2. For the arrangement refer to the current

spare parts list.
Insert outer clutch disks and inner clutch

disks. (1).
Fig. 30
EN 4474.751.113 - 2020-10 41
3. Insert end shim (1).
Fig. 31
If delivered in individual parts, assemble planetary gear
4. Place the cylindrical roller bearing (1) with

packaging sleeve (2) onto planetary gear (4).
5. Press the cylindrical roller bearing (1) through

packaging sleeve (2) into planetary gear (4),
until snap ring (3) engages audibly.
Fig. 32
1 Cylindrical roller bearing

2 Packaging sleeve
3 Snap ring
4 Planetary gear
42 EN 4474.751.113 - 2020-10
6.
Risk of burn injuries due to contact with hot

surfaces.
ð Wear protective gloves.
Heat the bearing inner rings of the cylindrical

roller bearings.
7. Push the planetary gears onto the planetary

carrier until contact is obtained. Slide on
cylindrical roller bearing with the large radius
facing downwards. Fig. 33
8. Let bearing inner rings cool down.
9. Adjust the bearing inner rings.
10. Insert retaining rings.
à Brake disks are exchanged.
EN 4474.751.113 - 2020-10 43
Dismantling
10 Dismantling
10.1 Removing and disassembling output and brake
10.1.1 Removing output
Special tools:
• AA01.395.095 Load carrying fixture
1. Remove breather valve (1).
Fig. 34
2. Use AA01.395.095 [Load carrying fixture]

and wheel nut to fasten output to crane.
3. Loosen hexagon screws.
4.

Separate output from axle housing.

Fig. 35
44 EN 4474.751.113 - 2020-10
Dismantling
5. Remove stub shaft.
6. Remove shim ring.
7. Remove sun gear shaft.
Fig. 36
10.1.2 Dismantling output for variant with combined seal
Special tools:
• 5870.300.017 Extracting device
• 5870.204.076 Eye nut
• 5870.204.073 Eyebolt
• 5873.014.016 Rapid grip
• 5873.004.001 Basic device
• AA01.061.332 Load ring
• 5870.400.001 Offset screwdriver
• 5873.014.013 Rapid grip
1.


Fig. 37
EN 4474.751.113 - 2020-10 45
Dismantling
2. Turn output by 90°.
3.
Risk of injury due to parts flying away.

ð Wear protective goggles.
Remove cover.
Fig. 38
4. Loosen locking screws and remove the

releasing cover.
Fig. 39
6. Press the planetary carrier out of the output

shaft using a two-armed extractor.
Fig. 40
46 EN 4474.751.113 - 2020-10
Dismantling
7. Variant with 4 planetary gears:

Use 5870.300.017 [Extracting device],
5870.204.076 [Eye nut] and crane to lift the
planetary carrier out of the brake housing.

5870.204.073 [Eyebolt] and crane to lift the
Fig. 41
9. Use 5873.014.016 [Rapid grip] and

5873.004.001 [Basic device] to pull bearing
inner ring from planetary carrier.
Fig. 42
Fig. 43
EN 4474.751.113 - 2020-10 47
Dismantling
Fig. 44
12. Remove end shim.
Fig. 45
13. Remove disk package.
Fig. 46
48 EN 4474.751.113 - 2020-10
Dismantling
15. Remove cover.
16. Remove cup spring.
17. Remove washer.
Fig. 47
18. Turn in breather valve (1) and tighten it by

hand.
19.

Press piston (2) out of brake housing using

compressed air.

Fig. 48
21. Remove guide ring (1).
22. Remove support ring and grooved ring (2).
23. Remove grooved ring and support ring (3).
Fig. 49
EN 4474.751.113 - 2020-10 49
Dismantling
24. Use two AA01.061.332 [Load ring] and a

crane to lift the brake housing from the
output shaft.
Fig. 50
25. Remove combined seal from the brake

housing using 5870.400.001 [Offset
screwdriver].
26. Remove the bearing outer rings from the

brake housing.
Fig. 51
27. Use 5870.400.001 [Offset screwdriver] to

remove the combined seal from the output
shaft.
Visually inspect the screening plate of the
combined seal for running-in wear.
Fig. 52
50 EN 4474.751.113 - 2020-10
Dismantling
28. Pull off tapered roller bearing with

5873.014.013 [Rapid grip] and
5873.004.001 [Basic device].
Fig. 53
10.1.3 Dismantling output for variant with slide ring seal
Special tools:
• 5870.204.076 Eye nut
• 5870.204.073 Eyebolt
• 5873.014.016 Rapid grip
• 5873.014.013 Rapid grip
1.


Fig. 54
EN 4474.751.113 - 2020-10 51
Dismantling
3.

Remove cover.
Fig. 55
4. Loosen locking screws and remove the

releasing cover.
Fig. 56
6. Press the planetary carrier out of the output

shaft using a two-armed extractor.
Fig. 57
52 EN 4474.751.113 - 2020-10
Dismantling

5870.204.076 [Eye nut] and crane to lift the

5870.204.073 [Eyebolt] and crane to lift the
Fig. 58

5873.004.001 [Basic device] to pull bearing
inner ring from planetary carrier.
Fig. 59
Fig. 60
EN 4474.751.113 - 2020-10 53
Dismantling
Fig. 61
12. Remove end shim.
Fig. 62
Fig. 63
54 EN 4474.751.113 - 2020-10
Dismantling
15. Remove cover.
16. Remove cup spring.
17. Remove washer.
Fig. 64
18. Turn in breather valve (1) and tighten it by

hand.
19.

Press piston (2) out of brake housing using

compressed air.

Fig. 65
21. Remove guide ring (1).
22. Remove support ring and grooved ring (2).
23. Remove grooved ring and support ring (3).
Fig. 66
EN 4474.751.113 - 2020-10 55
Dismantling
24. Use two AA01.061.332 [Load ring] and a

crane to lift the brake housing from the
output shaft.
Fig. 67
25. Remove slide ring seal from brake housing

using 5870.400.001 [Offset screwdriver].
26. Remove the bearing outer rings from the

brake housing.
Fig. 68
27. Use 5870.400.001 [Offset screwdriver] to

remove the slide ring seal from the output
shaft.
Fig. 69
56 EN 4474.751.113 - 2020-10
Dismantling
28. Pull off tapered roller bearing with

5873.014.013 [Rapid grip] and
5873.004.001 [Basic device].
Fig. 70
10.2 Dismantling axle housing, input and differential for variant with DHL/DL/D-2400
10.2.1 Removing and dismantling axle housing
1. Fasten axle housing to crane with lifting

device.
3.

Separate axle housing from axle drive

housing. Fig. 71
EN 4474.751.113 - 2020-10 57
Dismantling
4. Loosen bolted connection.
5. Loosen hexagon nut and remove brake tube.
Fig. 72
6. Loosen screw-in sleeve.
Fig. 73
7. Pull the bearing outer ring out of the axle

housing bore and remove the shim.
8. Remove O‑ring (1).
Fig. 74
58 EN 4474.751.113 - 2020-10
Dismantling
10.2.2 Dismantling input
Special tools:
• 5870.281.083 Load-lifting equipment
• 5870.401.139 Slotted nut wrench
• 5870.240.002 Locking mechanism
• AA00.338.279 Clamp
• AA00.684.425 Gripping device
• 5873.002.000 Basic tool
1. Lift differential out of axle drive housing using

5870.281.083 [Load-lifting equipment] and
crane.
Fig. 75
2. Pull the bearing outer ring (1) out of the axle

Fig. 76
EN 4474.751.113 - 2020-10 59
Dismantling
3.

For the variant with multi-disk differential lock

DHL‑2400 use compressed air to press the
piston out of the axle housing and remove it.
Fig. 77
4. Carry out the following two work steps

immediately one after the other.
Heat slotted nut.
5.

surfaces.
Loosen slotted nut with

Fig. 78
5870.401.139 [Slotted nut wrench] and
5870.240.002 [Locking mechanism].
6. Remove washer.
7. Pull input flange off the pinion.
60 EN 4474.751.113 - 2020-10
Dismantling
8. Remove shaft seal from axle drive housing

Fig. 79
9. Use the hexagon screws to attach the

AA00.338.279 [Clamp].
10. Press the pinion out of the axle drive housing

and remove the releasing bearing inner ring.
Fig. 80
11. Remove spacer ring from the pinion.
12. Pull off bearing inner ring with

AA00.684.425 [Gripping device] and
5873.002.000 [Basic tool].
Fig. 81
EN 4474.751.113 - 2020-10 61
Dismantling
13.

Force out bearing outer rings.
Fig. 82
10.2.3 Dismantling multi-disk differential lock DHL‑2400
Special tools:
• 5873.002.001 Basic tool
• 5873.003.029 Gripping device
• 5873.003.011 Reduction
• 5870.100.075 Pressure piece
1. Remove axial roller cage.
Fig. 83
62 EN 4474.751.113 - 2020-10
Dismantling
2.
Risk of crushing due to hydraulic tool.

Slight to moderate injury possible.
ð Do not reach into danger area.
Use AA01.195.394 [Gripping device] and

5873.002.001 [Basic tool] to pull the bearing
inner ring on crown wheel side off the
differential.
3. Use 5873.003.029 [Gripping device],

5873.002.001 [Basic tool],
5873.003.011 [Reduction] and Fig. 84
5870.100.075 [Pressure piece] to pull bearing
inner ring on the opposite side off the
differential.
4.

Fix differential using 5870.100.075 [Pressure

piece] and press.
6. Remove the housing cover.
Fig. 85
7. Preload housing cover and compression

spring with press.
8. Remove retaining ring.
9. Slowly release press.
10. Remove sliding sleeve and compression

spring.
Fig. 86
EN 4474.751.113 - 2020-10 63
Dismantling
11. Remove pressure piece (1), cage (2), twelve

pieces of lever (3), disk carrier (4) and disk
package (5).
Fig. 87
12.

Use press to fix differential.
13. Loosen locking screws.
Fig. 88
15. Remove axle bevel gear with thrust washers

from the differential.
Fig. 89
64 EN 4474.751.113 - 2020-10
Dismantling
16.

Force out slotted pins.
Fig. 90
17.

Force out the two short differential shafts.
18. Remove differential bevel gears and thrust

washers from the differential housing.
Fig. 91
19. Remove the long differential shaft.

Fig. 92
EN 4474.751.113 - 2020-10 65
Dismantling
21. Remove axle bevel gear.
22. Remove thrust washers.
Fig. 93
23.

Press crown wheel from differential housing.
Fig. 94
10.2.4 Dismantling multi-disk differential lock DL‑2400
Special tools:
• 5873.012.016 Rapid grip
• 5873.002.001 Basic tool
66 EN 4474.751.113 - 2020-10
Dismantling
1. Pull both bearing inner rings off the

differential using 5873.012.016 [Rapid grip]
and 5873.002.001 [Basic tool].
Fig. 95
2.

Fig. 96
5. Remove axle bevel gear with pressure ring,

disk package and thrust washers from the
differential.
Fig. 97
EN 4474.751.113 - 2020-10 67
Dismantling
6. Remove spider shafts and differential bevel

gears from the differential.
Fig. 98
Fig. 99
8. Remove pressure ring.
Fig. 100
68 EN 4474.751.113 - 2020-10
Dismantling
11.

Fig. 101
10.2.5 Dismantling differential D‑2400
Special tools:
• 5873.012.016 Rapid grip
• 5873.002.001 Basic tool
1. Pull both bearing inner rings off the

differential using 5873.012.016 [Rapid grip]
and 5873.002.001 [Basic tool].
Fig. 102
EN 4474.751.113 - 2020-10 69
Dismantling
2. Use press to fix differential.
Fig. 103
5. Use press to fix differential.
Fig. 104
8. Remove axle bevel gear with thrust washers

from the differential.
Fig. 105
70 EN 4474.751.113 - 2020-10
Dismantling
9.

Fig. 106
10.

Force out the two short differential shafts.

Fig. 107

Fig. 108
EN 4474.751.113 - 2020-10 71
Dismantling
Fig. 109
16. Press crown wheel from differential housing.
Fig. 110
72 EN 4474.751.113 - 2020-10
Dismantling
10.3 Dismantling axle housing, input and differential for variant with DHL/DZ/D-2700
10.3.1 Removing and dismantling axle housing
1. Fasten axle housing to crane with lifting

device.
3.

Separate axle housing from axle drive

housing. Fig. 111
4. Pull the bearing outer ring out of the axle

5. Remove O-ring from axle housing.
Fig. 112
EN 4474.751.113 - 2020-10 73
Dismantling
6.

For the variant with multi-disk differential lock

DHL‑2700 use compressed air to press the
piston (1) out of the axle housing.
Fig. 113
7. Loosen bolted connection.
8. Loosen the hexagon nut and remove the

brake tube.
Fig. 114
9. Loosen screw-in sleeve.
Fig. 115
74 EN 4474.751.113 - 2020-10
Dismantling
10.3.2 Dismantling input
Special tools:
• AA00.338.279 Clamp
• 5873.002.000 Basic tool

5870.281.083 [Load-lifting equipment] and
crane.
Fig. 116
2. Pull the bearing outer ring (1) out of the axle

Fig. 117
EN 4474.751.113 - 2020-10 75
Dismantling

Heat slotted nut.
4.

surfaces.
Loosen slotted nut with

Fig. 118
5. Remove washer.
7. Remove shaft seal from axle drive housing

Fig. 119
76 EN 4474.751.113 - 2020-10
Dismantling
8. Use the hexagon screws to attach the

AA00.338.279 [Clamp].
9. Press the pinion out of the axle drive housing

and remove the releasing bearing inner ring.
Fig. 120
10. Remove spacer ring from the pinion.
11. Pull off bearing inner ring with

AA00.684.425 [Gripping device] and
5873.002.000 [Basic tool].
Fig. 121
12.

Force out both bearing outer rings.
Fig. 122
EN 4474.751.113 - 2020-10 77
Dismantling
10.3.3 Dismantling multi-disk differential lock DHL‑2700
Special tools:
• AA02.233.363 Rapid grip
• 5873.012.016 Rapid grip
• 5873.002.001 Basic tool
• 5870.100.074 Assembly fixture
1. Remove the axial roller cage (1).
Fig. 123
2. Use AA02.233.363 [Rapid grip],

5870.100.075 [Pressure piece] and
5873.003.001 [Basic device] to pull the
bearing inner ring on crown wheel side off
the differential.
Fig. 124
78 EN 4474.751.113 - 2020-10
Dismantling
3. Rotate the differential by 180° and place it in

the 5870.100.075 [Pressure piece].

inner ring off the differential.
Fig. 125
5.

Fix differential using 5870.100.075 [Pressure

piece] and press.
6. Loosen locking screws .
Fig. 126
8. Preload compression spring with

5870.100.074 [Assembly fixture] and press.
9. Remove retaining ring .
10. Slowly release press.
11. Remove sliding sleeve and compression

spring.
Fig. 127
EN 4474.751.113 - 2020-10 79
Dismantling
12. Remove disk (1), thrust piece (2), cage (3),

twelve pieces of levers (4), disk carrier (5),
and the multi-disk package (6).
Fig. 128
13. Remove the disk (1) from the differential

housing.
Fig. 129
14. Remove the axle bevel gear (1), the inner

clutch disk and the outer clutch disk.
Fig. 130
80 EN 4474.751.113 - 2020-10
Dismantling
15.

Fig. 131
16.

Force out the short differential shafts.

washers.
Fig. 132

washers.
Fig. 133
EN 4474.751.113 - 2020-10 81
Dismantling
20. Remove axle bevel gear (1).
21. Remove inner clutch disk.
22. Remove outer clutch disk.
Fig. 134
23. Remove the compensating ring (1).
Fig. 135
24.

Fig. 136
82 EN 4474.751.113 - 2020-10
Dismantling
10.3.4 Dismantling differential DZ‑2700
Special tools:
• AA02.623.325 Load-lifting equipment
• 5873.002.001 Basic tool
1. Use AA02.623.325 [Load-lifting equipment]

to lift differential into support (1).
à Bearing cage is freely movable.
Fig. 137
2. Use AA01.195.394 [Gripping device] and

Fig. 138
EN 4474.751.113 - 2020-10 83
Dismantling

Fig. 139
4.

Use AA02.623.325 [Load-lifting equipment]

to lift differential into the press.
5.

Slight to moderate injury possible. Fig. 140
84 EN 4474.751.113 - 2020-10
Dismantling
8. Lift axle bevel gear and disk package out of

the differential housing.
9. Remove disk package from axle bevel gear.
Fig. 141
10.

Fig. 142
11.


washers.
Fig. 143
EN 4474.751.113 - 2020-10 85
Dismantling

washers.
Fig. 144
Fig. 145
16. Remove disk package (1).
Fig. 146
86 EN 4474.751.113 - 2020-10
Dismantling
17.

Fig. 147
10.3.5 Dismantling differential D‑2700
Special tools:
• 5873.002.001 Basic tool

to lift differential into support (1).
Fig. 148
EN 4474.751.113 - 2020-10 87
Dismantling

inner ring on crown wheel side off the
differential.
Fig. 149

inner ring on the opposite side off the
differential.
Fig. 150
4.

Use AA02.623.325 [Load-lifting equipment]

to lift differential into the press.
5.

Slight to moderate injury possible. Fig. 151
88 EN 4474.751.113 - 2020-10
Dismantling
8. Lift axle bevel gear (1), inner clutch disk (2),

outer clutch disk (3) and compensating ring
(4) out of the differential housing.
9. Remove compensating ring, outer clutch disk

and inner clutch disk from the axle bevel
gear.
Fig. 152
10.

Fig. 153
11.


washers.
Fig. 154
EN 4474.751.113 - 2020-10 89
Dismantling

washers.
Fig. 155
Fig. 156
16. Remove inner clutch disk, outer clutch disk

and compensating ring (1).
Fig. 157
90 EN 4474.751.113 - 2020-10
Dismantling
17.

Fig. 158
EN 4474.751.113 - 2020-10 91
Testing, Measuring, Adjusting
11 Testing, Measuring, Adjusting
11.1 Shim tables for variant with DHL/DL/D-2400
11.1.1 Shim tables
Rolling torque of the differential bearing and backlash are set using the shim tables. The required shims
result from block gage deviation and crown wheel deviation.
Deviation block gage [mm] (block gage Crown wheel deviation Shim on crown Shim on differential
361 mm) [mm] wheel side [mm] case side [mm]
–0.19 to –0.1 –0.2 1.4 0.8
–0.1 1.3 0.9
0.0 1.2 1.0
0.1 1.1 1.1
–0.09 to 0 –0.2 1.4 0.7
–0.1 1.3 0.8
0.0 1.2 0.9
0.1 1.1 1.0
0.01 to 0.1 –0.2 1.3 0.7
–0.1 1.2 0.8
0.0 1.1 0.9
0.1 1.0 1.0
0.11 to 0.2 –0.2 1.3 0.6
–0.1 1.2 0.7
0.0 1.1 0.8
0.1 1.0 0.9
0.21 to 0.3 –0.2 1.2 0.6
–0.1 1.1 0.7
0.0 1.0 0.8
0.1 0.9 0.9
Tab. 5 Shim table D‑2400 HK, DL‑2400 HK
390.33 mm) [mm] wheel side [mm] case side [mm]
–0.25 to –0.16 –0.2 1.4 0.8
–0.1 1.3 0.9
0.0 1.2 1.0
0.1 1.1 1.1
–0.15 to –0.06 –0.2 1.3 0.8
–0.1 1.2 0.9
0.0 1.1 1.0
0.1 1.0 1.1
–0.05 to 0.04 –0.2 1.3 0.7
–0.1 1.2 0.8
0.0 1.1 0.9
0.1 1.0 1.0
0.05 to 0.14 –0.2 1.2 0.7
–0.1 1.1 0.8
0.0 1.0 0.9
0.1 0.9 1.0
92 EN 4474.751.113 - 2020-10
0.15 to 0.24 –0.2 1.2 0.6
–0.1 1.1 0.7
0.0 1.0 0.8
0.1 0.9 0.9
Tab. 6 Shim table DHL‑2400 HK
11.2 Shim tables for variant with DHL/DZ/D-2700
11.2.1 Shim tables
Rolling torque of the differential bearing and backlash are set using the shim table. The required shims
result from block gage deviation and crown wheel deviation.
0.21 to 0.25 –0.20 1.00 0.80
–0.10 0.90 0.90
0.00 0.80 1.00
0.10 0.70 1.10
0.26 to 0.30 –0.20 0.95 0.80
–0.10 0.85 0.90
0.00 0.75 1.00
0.10 0.65 1.10
0.31 to 0.35 –0.20 0.95 0.75
–0.10 0.85 0.85
0.00 0.75 0.95
0.10 0.65 1.05
0.36 to 0.40 –0.20 0.90 0.75
–0.10 0.80 0.85
0.00 0.70 0.95
0.10 0.60 1.05
0.41 to 0.45 –0.20 0.90 0.70
–0.10 0.80 0.80
0.00 0.70 0.90
0.10 0.60 1.00
0.46 to 0.50 –0.20 0.85 0.70
–0.10 0.75 0.80
0.00 0.65 0.90
0.10 0.55 1.00
0.51 to 0.55 –0.20 0.85 0.65
–0.10 0.75 0.75
0.00 0.65 0.85
0.10 0.55 0.95
0.56 to 0.60 –0.20 0.80 0.65
–0.10 0.70 0.75
0.00 0.60 0.85
0.10 0.50 0.95
EN 4474.751.113 - 2020-10 93
0.61 to 0.65 –0.20 0.80 0.60
–0.10 0.70 0.70
0.00 0.60 0.80
0.10 0.50 0.90
0.66 to 0.70 –0.20 0.75 0.60
–0.10 0.65 0.70
0.00 0.55 0.80
0.10 0.45 0.90
0.71 to 0.75 –0.20 0.75 0.55
–0.10 0.65 0.65
0.00 0.55 0.75
0.10 0.45 0.85
0.76 to 0.80 –0.20 0.70 0.55
–0.10 0.60 0.65
0.00 0.50 0.75
0.10 0.40 0.85
0.81 to 0.85 –0.20 0.70 0.50
–0.10 0.60 0.60
0.00 0.50 0.70
0.10 0.40 0.80
0.86 to 0.90 –0.20 0.65 0.50
–0.10 0.55 0.60
0.00 0.45 0.70
0.10 0.35 0.80
0.91 to 0.95 –0.20 0.65 0.45
–0.10 0.55 0.55
0.00 0.45 0.65
0.10 0.35 0.75
Tab. 7 Shim table D‑2700 HK, DZ‑2700 HK
0.08 to 0.12 –0.20 1.00 0.80
–0.10 0.90 0.90
0.00 0.80 1.00
0.10 0.70 1.10
0.13 to 0.17 –0.20 0.95 0.80
–0.10 0.85 0.90
0.00 0.75 1.00
0.10 0.65 1.10
0.18 to 0.22 –0.20 0.95 0.75
–0.10 0.85 0.85
0.00 0.75 0.95
0.10 0.65 1.05
0.23 to 0.27 –0.20 0.90 0.75
–0.10 0.80 0.85
0.00 0.70 0.95
0.10 0.60 1.05
94 EN 4474.751.113 - 2020-10
0.28 to 0.32 –0.20 0.90 0.70
–0.10 0.80 0.80
0.00 0.70 0.90
0.10 0.60 1.00
0.33 to 0.37 –0.20 0.85 0.70
–0.10 0.75 0.80
0.00 0.65 0.90
0.10 0.55 1.00
0.38 to 0.42 –0.20 0.85 0.65
–0.10 0.75 0.75
0.00 0.65 0.85
0.10 0.55 0.95
0.43 to 0.47 –0.20 0.80 0.65
–0.10 0.70 0.75
0.00 0.60 0.85
0.10 0.50 0.95
0.48 to 0.52 –0.20 0.80 0.60
–0.10 0.70 0.70
0.00 0.60 0.80
0.10 0.50 0.90
0.53 to 0.57 –0.20 0.75 0.60
–0.10 0.65 0.70
0.00 0.55 0.80
0.10 0.45 0.90
0.58 to 0.62 –0.20 0.75 0.55
–0.10 0.65 0.65
0.00 0.55 0.75
0.10 0.45 0.85
0.63 to 0.67 –0.20 0.70 0.55
–0.10 0.60 0.65
0.00 0.50 0.75
0.10 0.40 0.85
0.68 to 0.72 –0.20 0.70 0.50
–0.10 0.60 0.60
0.00 0.50 0.70
0.10 0.40 0.80
0.73 to 0.77 –0.20 0.65 0.50
–0.10 0.55 0.60
0.00 0.45 0.70
0.10 0.35 0.80
0.78 to 0.82 –0.20 0.65 0.45
–0.10 0.55 0.55
0.00 0.45 0.65
0.10 0.35 0.75
Tab. 8 Shim table DHL‑2700 HK
EN 4474.751.113 - 2020-10 95
11.3 Checking contact pattern (Gleason‑gearing)
Ideal contact pattern of the crown wheel.
1 Crown wheel convex (drive side)

2 Crown wheel concave (coast side)
Fig. 159 Ideal contact pattern
Indicators of an ideal contact pattern:

• It is tangent to the tooth centerline.
• Is tangent at least half as wide as the tooth is high.
• Is approximately in the center area between crown wheel inner side and crown wheel outer side.
• It looks similar on the convex and the concave side.
A visible line caused by the shot-peening process is

allowed.
Fig. 160 Shot-peening edge
1 Shot-peening edge
The possible deviations and required correction measures are described in the following sections.
96 EN 4474.751.113 - 2020-10
11.3.1 Contact pattern on crown wheel shifted towards the root
• Contact pattern is shifted towards the root.

• Contact pattern is tangent on the convex flank on the inner side of the crown wheel and on the
concave flank on the outer side of the crown wheel.
1. Install the thinner pinion spacer on the input.
2. Set backlash.
3. Check contact pattern.
Fig. 161 Dedendum tooth position

11.3.2 Contact pattern on crown wheel shifted towards the tip
• Contact pattern is shifted towards the tip.

• Contact pattern is too small.
• Contact pattern is not tangent to the tooth centerline.
1. Install thicker pinion spacer on input.
2. Set backlash.
Fig. 162 Addendum tooth position

EN 4474.751.113 - 2020-10 97
11.3.3 Special case "Line" contact pattern
• Contact pattern is visible as line.

• Contact pattern is shifted towards the tip.
1. Insert a thicker pinion spacer on the input.
2. Setting backlash
Fig. 163 Addendum tooth position with "line" contact pattern

4. This contact pattern is not ideal but

acceptable as it presses off on more
than half the tooth height. Also, this
contact pattern is tangent to the tooth at
half tooth height.
In order to optimize the contact pattern,

insert a thicker pinion spacer on the input.
5. Setting backlash
Fig. 164 "Line" contact pattern

11.4 Selecting the cover for adjusting the output shaft bearing
The output shaft bearing is adjusted with the cover. Select the required cover based on the distance
determined.
98 EN 4474.751.113 - 2020-10
Distance from the front face of the output shaft to the front face Offset to be used on the cover ZF order number
of the planetary carrier
0.30 mm to 0.20 mm 0.13 mm ± 0.01 mm 4474.353.172
0.199 mm to 0.14 mm 0.07 mm ± 0.01 mm
0.139 mm to 0.02 mm 0.0mm 4474.353.115
Tab. 9 Cover
Cover 4474.353.172 has different offsets. Offset with 0.13 mm is marked with a groove
11.5 Backlash
Backlash (mm) Ratio bevel gearset i

0.32 to 1.06 3.08
0.35 to 1.15 3.364
0.40 to 1.33 3.89
0.42 to 1.41 4.11
Tab. 10
EN 4474.751.113 - 2020-10 99
Assembly
12 Assembly
12.1 Assembling differential, input and axle housing for variant with DHL/DL/D-2400
12.1.1 Assembling multi-disk differential lock DHL-2400
Special tools:
• 5870.204.040 Fixing pin
• 5870.700.004 Load cell
• AA00.331.446 Lifting device
1. Turn in two 5870.204.040 [Fixing pin].
2.

surfaces.

ð Do not reach into danger area. Fig. 165
Heat crown wheel and press on differential

3. Place thrust washers into differential housing.
Fig. 166
100 EN 4474.751.113 - 2020-10

Assembly
4. Insert axle bevel gear.
Fig. 167
5. Insert two differential bevel gears and two

thrust washers with the tab (1) facing
upwards.
6. Insert long differential shaft.
Fig. 168

upwards.
8. Vertically align holes of the short differential

shafts and slide the differential shafts in.
9. Check that the holes of the differential shafts

are aligned with the fixing holes (2).
Fig. 169
EN 4474.751.113 - 2020-10 101

Assembly
10.

Flush-mount slotted pins.
Fig. 170
Fig. 171
12. Insert thrust washers with grease into the

housing cover.
Fig. 172
102 EN 4474.751.113 - 2020-10

Assembly
14. Slide on the housing cover.
15.

16. Turn in new locking screws and tighten.

Tightening torque: 400 Nm Fig. 173
17. Slide compression spring onto the sliding

sleeve.
Fig. 174
18. Place housing cover onto compression

spring.
19. Preload compression spring with press.
20. Insert retaining ring into annular groove of

sliding sleeve.
Fig. 175
EN 4474.751.113 - 2020-10 103

Assembly
Setting disk clearance

spare parts list.
Install individual parts.
Fig. 176
1 Housing cover
2 Pressure piece
3 Cage
4 12 pieces of lever
5 Disk carrier
6 Thrust collar
7 Inner clutch disks
8 Outer clutch disks (various thicknesses are available)
9 Snap ring
22. Insert housing cover into hydraulic press and

support it on the supporting surface (1).
40_070091_01
Fig. 177
104 EN 4474.751.113 - 2020-10

Assembly
23. Place 5870.100.069 [Assembly fixture] on the

disk package.
24.

Preload disk package with

5870.700.004 [Load cell] and
5870.100.069 [Assembly fixture] with an
axial force of F = 50 kN +30 kN.
Fig. 178
25. Check disk clearance of the multi-disk
differential lock 1.05 mm ±0.1 mm from the
collar of the differential cover to the plane
surface of the outer disk.
If the disk clearance deviates, install other
outer clutch disks.
26. Place housing cover on

5870.100.075 [Pressure piece] (1).
27. Align disk package in housing cover from

below with two hexagon screws.
Fig. 179
EN 4474.751.113 - 2020-10 105

Assembly
28. Place differential onto housing cover using

AA00.331.446 [Lifting device].
29. Turn in two hexagon screws.
30. Hand-tighten hexagon screws.
Fig. 180
31.

Fix differential using press and

5870.100.075 [Pressure piece].
32. Turn in remaining hexagon screws and

tighten them by hand.
Tightening torque: 185 Nm
Fig. 181
33.

surfaces.
Heat up both bearing inner rings.
34. Slide on the bearing inner rings until contact

is obtained.

Fig. 182
36. Adjust bearing inner rings.
106 EN 4474.751.113 - 2020-10

Assembly
37. Apply grease to the axial roller cage.
38. Place the axial roller cage on the sliding

sleeve.
Fig. 183
12.1.2 Assembling multi-disk differential lock DL-2400
Special tools:
• 5870.204.040 Fixing pin
• 5870.200.022 Straightedge
2.

surfaces.


EN 4474.751.113 - 2020-10 107

Assembly
3. Place thrust washers in the differential

housing.
Fig. 185

spare parts list.
Insert outer and inner disks so that the

grooves on the inner diameter of the inner
disks are aligned.
The thickness of the disk packages must
not exceed a maximum of 0.1 mm.
Fig. 186
5. Insert pressure ring.
Fig. 187
108 EN 4474.751.113 - 2020-10

Assembly
6. Insert axle bevel gear into gearing of the

inner disks.
Fig. 188
7. Assemble spider shafts and differential bevel

gears and insert into pressure ring.
Fig. 189
Fig. 190
EN 4474.751.113 - 2020-10 109

Assembly
9. Insert pressure ring.
Fig. 191

spare parts list.
Insert outer and inner disks so that the

grooves on the inner diameter of the inner
disks are aligned.
Fig. 192
11. Measure distance A from the mounting face

of the differential housing to the plane
surface of the outer disk using depth gage
and 5870.200.022 [Straightedge].
Distance A = e. g. 44.30 mm
Fig. 193
110 EN 4474.751.113 - 2020-10

Assembly
12. Measure distance B from the contact surface

of the outer disk to the mounting face of the
housing cover using depth gage.
Distance B = e.g. 43.95 mm
Fig. 194
13. Determine disk clearance of the multi-disk differential lock 0.2 mm to 0.7 mm.
Calculation example:
Disk clearance = Distance A – Distance B
Disk clearance = 44.30 mm – 43.95 mm
Disk clearance = 0.35 mm
In case of deviations from the reference dimension, install a thicker or thinner outer disk.
Try to reach a smaller value.
The thickness of the disk packages must not exceed a maximum of 0.1 mm.
14. Use grease to insert the thrust washer into

the housing cover.
Fig. 195
EN 4474.751.113 - 2020-10 111

Assembly
17.


19.

surfaces.

is obtained.

Fig. 197
12.1.3 Assembling differential D-2400
Special tools:
• 5870.204.040 Fixing pin
112 EN 4474.751.113 - 2020-10

Assembly
2.

surfaces.


3. Place thrust washers in the differential

housing.
Fig. 199
Fig. 200
EN 4474.751.113 - 2020-10 113

Assembly

upwards.
6. Slide long differential shaft in.
Fig. 201

upwards.
8. Vertically align holes of the short differential

shafts and slide the differential shafts in.
9. Check if holes of differential shafts are

aligned with fixing holes (2).
Fig. 202
10.

Flush-mount slotted pins.
Fig. 203
114 EN 4474.751.113 - 2020-10

Assembly
Fig. 204
12. Use grease to insert the thrust washers into

the housing cover.
Fig. 205
15.


EN 4474.751.113 - 2020-10 115

Assembly
17.

18. Turn in and tighten hexagon screws.

Fig. 207
19.

surfaces.

is obtained.

Fig. 208
12.1.4 Assembling input
Special tools:
• 5870.058.079 Driver tool
• 5870.260.004 Handle
• AA00.848.434 Measuring disk
• AA00.860.154 Measuring support
• 5870.204.024 Fixing pin
116 EN 4474.751.113 - 2020-10

Assembly
• AA01.364.201 Test device

• AA02.039.663 Screw coupling
• 5870.286.079 Fitting
• AA02.052.369 Driver tool
Operating supplies and auxiliary materials:

• 0666.690.191 PHÖNIX SPIRITUS
• 0666.690.022 LOCTITE 262
1. If crown wheel or drive pinion are

damaged, both parts must be replaced
simultaneously.
When dismantling use disassembled

shims. Replace damaged shims by new
shims with identical thickness.
Insert shim into bearing hole.
Fig. 209

Risk of burn injuries due to contact with cold

surface.
Undercool outer bearing outer ring.
3. Insert bearing outer ring with

5870.058.079 [Driver tool] and Fig. 210
5870.260.004 [Handle] until contact is
obtained.
EN 4474.751.113 - 2020-10 117

Assembly


surfaces.
Undercool inner bearing outer ring.
5. Use 5870.345.080 [Assembly fixture] to pull

the bearing outer ring into the bearing hole Fig. 211
until contact is obtained.
Setting rolling torque of pinion bearing


surfaces.
Heat bearing inner ring.
7. Slide the bearing inner ring onto pinion until

contact is obtained. Fig. 212
8. Let bearing inner ring cool down.
9. Adjust bearing inner ring.
118 EN 4474.751.113 - 2020-10

Assembly
10. Use the spacer ring removed during

disassembly. If damaged, replace spacer
ring by a new one of the same
thickness.
Slide on spacer ring with e.g. s = 8.18 mm.
Fig. 213
11. Carry out the following three work steps


surfaces.
12. Insert the pinion into the axle drive housing.

Fig. 214
13. Slide heated bearing inner ring onto pinion
EN 4474.751.113 - 2020-10 119

Assembly
16.

Force guard plate (1) onto the input flange

Fig. 215
17. Slide on input flange.
18. Slide on shim.
19. Install slotted nut without Loctite for the

time being.
When tightening rotate drive pinion

several times in both directions.
Use 5870.401.139 [Slotted nut wrench] and

5870.240.002 [Locking mechanism] to
tighten the slotted nut.
Tightening torque: 1,200 Nm Fig. 216
20. Check required Rolling torque of pinion

bearing 1.5 Nm to 4 Nm.
In case of insufficient rolling torque, install a
thinner spacer ring.
In case of excessive rolling torque, install a
thicker spacer ring.
When assembling new bearings try to

achieve the upper value of the rolling
torque.
Fig. 217
120 EN 4474.751.113 - 2020-10

Assembly
Variant with DHL-2400: Installing piston.
21. Grease O‑rings.
22. Insert O‑rings into the annular grooves (1) of

the piston.
Fig. 218
23. Insert piston (1) into the bearing housing until

Fig. 219
Adjusting differential bearing rolling torque and backlash
24. Differential bearing rolling torque and

backlash result from crown wheel deviation
and block gage deviation. See shim tables for
the corresponding thickness of the shims.
Read crown wheel deviation behind

installation dimension 101 [mm] (1).
Crown wheel deviation = e.g. -10 = -0.10 mm
If no deviation is indicated, the deviation
is equal to the value "0“.
Fig. 220
EN 4474.751.113 - 2020-10 121

Assembly
25. Insert bearing outer ring into

AA00.848.434 [Measuring disk] (1).
26.

Use AA00.331.446 [Lifting device] and crane

in order to insert the differential into the
bearing outer ring.
Fig. 221
27. Put bearing outer ring onto differential.
28. Rotate tapered roller bearings several times in

both directions.
29. Variant DHL‑2400: Put

AA00.848.397 [Measuring disk] (2) on
bearing outer ring.
Variant D‑2400, DL‑2400: Put
bearing outer ring.
30. Use the depth gage, the

5870.200.022 [Straightedge] and two
AA00.860.154 [Measuring support] in order
to determine the height of the measurement
setup.
Height of measurement setup = e. g.
410.88 mm
31. Calculate deviation from block gage shim tables.
Calculation example (DHL‑2400):

Deviation from block gage = height of measurement setup – block gage – height of
AA00.848.434 [Measuring disk] (2) – height of AA00.848.397 [Measuring disk] (1)
Deviation from block gage = 410.88 mm – 390.33 mm – 10 mm – 10 mm
Deviation from block gage = -0.55 mm
32. See shim tables for thickness of the shims.
122 EN 4474.751.113 - 2020-10

Assembly
33. Insert shim, which was determined for the

differential case side, into the bearing hole.
34. Insert bearing outer ring (1) until contact is

obtained.
Fig. 222
35. Cover some drive and coast flanks on the

crown wheel with marking paste.
36.

Use 5870.281.083 [Load-lifting equipment]

and crane to insert differential into axle drive
housing.
Fig. 223
37. Insert the shim, which was determined for

the crown-wheel side, into the bearing hole.
38. Insert bearing outer ring until contact is

obtained.
Fig. 224
EN 4474.751.113 - 2020-10 123

Assembly
40.

Use lifting device and crane to install the axle

housing on the axle drive housing.
41. Use the 5870.350.077 [Supporting bracket]

in order to support the axle housing. Fig. 225
42. Fix axle housing with four hexagon screws.

Checking backlash on input flange
43. Fix AA01.364.201 [Test device] to input

flange.
44. Set the dial gage on the AA01.364.201 [Test

device] at measuring point MP = 100 mm.
45. Read backlash on test device. Check value in

table backlash.
In case of insufficient backlash, install a
thicker shim for backlash and a thinner shim
for differential bearing rolling torque.
In case of excessive backlash, install a thinner
shim for backlash and a thicker shim for
differential bearing rolling torque.
Fig. 226
124 EN 4474.751.113 - 2020-10

Assembly
Variant with DHL-2400: Checking differential lock for tightness
46.
Possible property damage due to excessive

pressures.
ð Do not exceed indicated pressure.
Use the AA02.039.663 [Screw coupling] and

5870.286.079 [Fitting] to pressurize the lock
with compressed air p = 1.
47. Close shut-off valve.
48. Remove compressed air hose.

Fig. 227
49. Wait ten seconds.
50. Read pressure.
à After the waiting time, no pressure loss is

permissible.
If the pressure drops, disassemble the axle

housing and check the seals.
Checking contact pattern
51. Rotate input flange several times in both

directions.
52.

Remove axle housing.

5870.281.083 [Load-lifting equipment] and Fig. 228
crane.
54. Check contact pattern (refer to section

Checking contact pattern (Gleason‑gearing),
page 96).
EN 4474.751.113 - 2020-10 125

Assembly
When changing the shim, readjust the pinion

bearing rolling torque and the backlash.
Fitting shaft seal
55. Loosen slotted nut with

56. Remove washer.
Fig. 229
58. Apply grease to the inner diameter of the

shaft seal.

Apply 0666.690.191 [PHÖNIX SPIRITUS] to

outer diameter of shaft seal.
60. Use AA02.052.369 [Driver tool] to insert

shaft seal with sealing lip facing the oil
chamber.
In installation position in the vehicle the
marking (raised point) is at the top. Fig. 230
126 EN 4474.751.113 - 2020-10

Assembly
62. Slide on shim.
63. Apply 0666.690.022 [LOCTITE 262] onto

thread of slotted nut.
64. When tightening rotate drive pinion


65.


housing.
Fig. 232
12.1.5 Assembling and attaching axle housing
Special tools:
• 5870.204.024 Fixing pin
EN 4474.751.113 - 2020-10 127

Assembly
1. Grease O‑ring.
2. Push the O-ring (1) onto the axle housing.
Fig. 233
4.


5. Support axle housing using

5870.350.077 [Supporting bracket] and Fig. 234
5870.350.075 [Clamping fixture].
6. Fix axle housing with hexagon screws.

128 EN 4474.751.113 - 2020-10

Assembly
7. Turn in screw plug with new O‑ring and

tighten.
Fig. 235
8. Turn in screw-in sleeve and tighten.

Fig. 236
9. Grease O‑ring (1).
10. Insert O‑ring (1) into the annular groove of

the brake tube.
Fig. 237
EN 4474.751.113 - 2020-10 129

Assembly
11. Insert the brake tube into the axle housing.
12. Use hexagon nut (1) and the lock nut for
fixing the brake tube.
Fig. 238
12.2 Assembling differential, input and axle housing for variant with DHL/DZ/D-2700
12.2.1 Assembling the multi-disk differential lock DHL-2700
Special tools:
• 5870.204.040 Fixing pin
• 5870.700.004 Load cell
• 5870.204.076 Eye nut
1. Bolt two 5870.204.040 [Fixing pin] into the

crown wheel.
2.

surfaces.
Heat the crown wheel and press it onto

differential housing until contact is obtained.
Fig. 239
130 EN 4474.751.113 - 2020-10

Assembly
3. Insert the compensating ring (1) into the

differential housing.
Fig. 240
4. Insert the outer clutch disk (1) and inner

clutch disk (2).
Fig. 241
5. Insert axle bevel gear (1).
Fig. 242
EN 4474.751.113 - 2020-10 131

Assembly

thrust washers. Insert the lug of the thrust
washers (1) into the housing recess.
7. Insert long differential shaft .
Fig. 243

thrust washers. Insert the lug of the thrust
washers (1) into the housing recess.
9. Align short differential shafts radially and

insert.
10. Check that the bores of the differential shafts

are aligned with the fixing holes (2).
Fig. 244
11.

Position slotted pins with the slot showing in

circumferential direction and flush-mount
them.
Fig. 245
132 EN 4474.751.113 - 2020-10

Assembly
12. Slide compression spring onto the sliding

sleeve.
Fig. 246
13. Deposit housing cover onto compression

spring.
14. Preload compression spring with press.
15. Insert retaining ring into annular groove of

sliding sleeve.
Fig. 247

spare parts list.
Install individual parts.

• 1 = Housing cover
• 2 = Thrust piece
• 3 = Washer
• 4 = Cage
• 5 = 12 levers
• 6 = Outer clutch disk (s = 3.5 mm)
• 7 = disk carrier
• 8 = Outer clutch disks (various
thicknesses are available)
• 9 = Inner clutch disks Fig. 248
EN 4474.751.113 - 2020-10 133

Assembly
17. Support the housing cover in the hydraulic

press on the supporting surface (1).
Fig. 249
18.

Preload disk package with

5870.100.069 [Assembly fixture] and
5870.700.004 [Load cell] with an axial force
of F = 50 kN +30 kN.
19. Measure disk clearance of the multi-disk

differential lock 1.05 mm ±0.1 mm from the
front face of the housing cover to the plane Fig. 250
surface of the outer clutch disk.
In case of insufficient disk clearance, insert
thinner outer clutch disks.
In case of excessive disk clearance, insert
thicker outer clutch disks.
134 EN 4474.751.113 - 2020-10

Assembly
20. Place the housing cover onto the

5870.100.075 [Pressure piece] (1).
21. Position disk (2).
Fig. 251
22. Install the outer clutch disk (1) and inner

clutch disk (2).
Fig. 252
24. Ensure the outer clutch disk (2) is radially

aligned.
Fig. 253
EN 4474.751.113 - 2020-10 135

Assembly
25. Bolt two 5870.204.040 [Fixing pin] into the

crown wheel.
26. Use the 5870.300.017 [Extracting device],

5870.204.076 [Eye nut] and crane to place
the differential housing onto the housing
cover. Pay attention that the holes are
aligned.
27. Screw in two new locking screws and tighten

them by hand.
Fig. 254
28.

Fix differential using press and

5870.100.075 [Pressure piece].
29. Screw in new locking screws and tighten.

Fig. 255
30.

surfaces.

is obtained.

Fig. 256
136 EN 4474.751.113 - 2020-10

Assembly
34. Apply grease to the axial roller cage.
35. Place the axial roller cage (1) on the sliding

sleeve.
Fig. 257
12.2.2 Assembling differential DZ‑2700
Special tools:
• 5870.204.040 Fixing pin
1. Turn two 5870.204.040 [Fixing pin] into the

crown wheel.
2. Heat crown wheel.
3.

surfaces.
Slide crown wheel onto differential housing

until contact is obtained. Fig. 258
EN 4474.751.113 - 2020-10 137

Assembly
Setting thickness of disk package
4. Put on outer clutch disks and inner clutch

disks.
For the arrangement refer to the current
spare parts list.

5. Press on disk package by hand and measure

thickness of the disk package.
Thickness of disk package 19.80 mm to
20.00 mm
In case of insufficient thickness of the disk
package, put on a thicker outer clutch disk. Fig. 259
In case of excessive thickness of the disk
package, put on a thinner outer clutch disk.
6. Insert disk package (1).
Fig. 260
Fig. 261
138 EN 4474.751.113 - 2020-10

Assembly
8. Insert thrust washers and differential bevel

gears. Insert tab of the thrust washers into
the differential housing recess.
9. Insert long differential shaft (3).
Fig. 262
10. Insert thrust washers (2) and differential

bevel gears (1). Insert tab of the thrust
washers into the differential housing recess.
11. Insert short differential shafts (4) with slotted

pin hole being flush with the differential
housing hole (3).
Fig. 263
12. Centrically align the slotted pin hole in short

differential shaft to the differential housing
hole.
13.

Flush-mount slotted pins with slot showing in

circumferential direction.
Fig. 264
EN 4474.751.113 - 2020-10 139

Assembly
Fig. 265
15. Insert disk package (1) of the same thickness.

For the arrangement refer to the current
spare parts list.

Fig. 266
16. Insert housing cover into differential housing.
17.


Fig. 267
140 EN 4474.751.113 - 2020-10

Assembly
19.

surfaces.
20. Slide on bearing inner ring until contact is

obtained.
21. Adjust bearing inner ring after cooling-down.

Fig. 268

to lift differential onto support (1).
23.

surfaces.

Fig. 269
obtained.
12.2.3 Assembling differential D‑2700
Special tools:
• 5870.204.040 Fixing pin
EN 4474.751.113 - 2020-10 141

Assembly
1. Turn two 5870.204.040 [Fixing pin] into the

crown wheel.
2. Heat crown wheel.
3.

surfaces.
Slide crown wheel onto differential housing

until contact is obtained. Fig. 270
4. Insert compensating ring, outer clutch disk

and inner clutch disk (1).
Fig. 271
Fig. 272
142 EN 4474.751.113 - 2020-10

Assembly
6. Insert thrust washers and differential bevel

gears. Insert tab of the thrust washers into
the differential housing recess.
7. Insert long differential shaft (3).
Fig. 273
8. Insert thrust washers (2) and differential

bevel gears (1). Insert tab of the thrust
washers into the differential housing recess.
9. Insert short differential shafts (4) with slotted

pin hole being flush with the differential
housing hole (3).
Fig. 274
10. Centrically align the slotted pin hole in short

differential shaft to the differential housing
hole.
11.

Flush-mount slotted pins with the slot

showing in circumferential direction.
Fig. 275
EN 4474.751.113 - 2020-10 143

Assembly
Fig. 276
13. Put inner clutch disk, outer clutch disk and

compensating ring (1) onto the axle bevel
gear.
Fig. 277
14. Insert the housing cover into the differential

housing.
15.


Fig. 278
144 EN 4474.751.113 - 2020-10

Assembly
17.

surfaces.

obtained.

Fig. 279

to lift differential onto support (1).
21.

surfaces.

Fig. 280
obtained.
12.2.4 Assembling input
Special tools:
• 5870.058.079 Driver tool
• 5870.260.004 Handle
• AA00.860.154 Measuring support
EN 4474.751.113 - 2020-10 145

Assembly

• 5870.204.024 Fixing pin
• AA01.364.201 Test device
• 5870.286.079 Fitting
• AA02.052.369 Driver tool

• 0666.690.022 LOCTITE 262
1. If crown wheel or drive pinion are

damaged, both parts must be replaced
simultaneously.
When dismantling use disassembled

shims. Replace damaged shims by new
shims with identical thickness.
Insert shim into the bearing hole.
Fig. 281

Risk of burn injuries due to contact with cold

surface.
Undercool outer bearing outer ring.
3. Insert bearing outer ring with

5870.058.079 [Driver tool] and Fig. 282
5870.260.004 [Handle] until contact is
obtained.
146 EN 4474.751.113 - 2020-10

Assembly


surfaces.
Undercool inner bearing outer ring.
5. Use 5870.345.080 [Assembly fixture] to pull

the bearing outer ring into the bearing hole Fig. 283
Setting rolling torque of pinion bearing


surfaces.
7. Slide bearing inner ring onto pinion until

contact is obtained. Fig. 284
EN 4474.751.113 - 2020-10 147

Assembly
10. Use the spacer ring removed during

disassembly. If damaged, replace spacer
ring by a new one of the same
thickness.
Slide on spacer ring with e.g. s = 8.18 mm.
Fig. 285
11. Carry out the following three work steps


surfaces.
12. Insert the pinion into the axle drive housing.

Fig. 286
13. Push heated bearing inner ring onto piston
148 EN 4474.751.113 - 2020-10

Assembly
16.

Force guard plate (1) onto the input flange

Fig. 287
18. Slide on shim.
19. Install slotted nut without Loctite for the

time being.
When tightening, rotate drive pinion


20. Check required Rolling torque of pinion

bearing 1.5 Nm to 4 Nm.
In case of insufficient rolling torque, install a
thinner spacer ring.
In case of excessive rolling torque, install a
thicker spacer ring.
When assembling new bearings try to

achieve the upper value of the rolling
torque.
Fig. 289
EN 4474.751.113 - 2020-10 149

Assembly
Adjusting differential bearing rolling torque and backlash
21. Differential bearing rolling torque and

backlash result from crown wheel deviation
and block gage deviation. See shim tables for
the corresponding thickness of the shims.
Read crown wheel deviation behind

installation dimension 101 [mm] (1).
Crown wheel deviation = e.g. -10 = -0.10 mm
If no deviation is indicated, the deviation
is equal to the value "0“.
Fig. 290
22. Insert the outer bearing ring into

AA00.848.434 [Measuring disk] (1).
23.

Use AA00.331.446 [Lifting device] and crane

in order to insert the differential into the
bearing outer ring.
Fig. 291
24. Put bearing outer ring onto differential.
25. Rotate tapered roller bearings several times in

both directions.
26. Variant DHL‑2700: Put

bearing outer ring.
Variant D‑2700, DZ‑2700: Put
bearing outer ring.
27. Use the depth gage, the

5870.200.022 [Straightedge] and two
AA00.860.154 [Measuring support] in order
to determine the height of the measurement
setup.
150 EN 4474.751.113 - 2020-10

Assembly
Height of measurement setup = e. g.

410.88 mm
28. Calculate deviation from block gage shim tables.
Calculation example (DHL‑2700):

Deviation from block gage = height of measurement setup – block gage – height of
AA00.848.434 [Measuring disk] (2) – height of AA00.848.397 [Measuring disk] (1)
Deviation from block gage = 410.88 mm – 390.33 mm – 10 mm – 10 mm
Deviation from block gage = -0.55 mm
29. See shim tables for thickness of the shims.
30. Insert shim, which was determined for the

differential case side, into the bearing hole.

obtained.
Fig. 292
32. Cover some drive and coast flanks on the

crown wheel with marking paste.
33.


housing.
Fig. 293
EN 4474.751.113 - 2020-10 151

Assembly
Variant with DHL-2700: Installing piston
34. Grease O‑rings.
35. Insert O‑rings into the annular grooves (1) of

the piston.
Fig. 294
36. Insert the piston (1) into axle housing until

Fig. 295
37. Insert the shim, which was determined for

the crown wheel side, into the bearing hole.

obtained.
Fig. 296
152 EN 4474.751.113 - 2020-10

Assembly
40.


41. Use the 5870.350.077 [Supporting bracket]

in order to support the axle housing. Fig. 297
42. Fix axle housing with four hexagon screws.

Checking backlash on input flange
43. Fix AA01.364.201 [Test device] to input

flange.
44. Set the dial gage on the AA01.364.201 [Test

device] at measuring point MP = 100 mm.
45. Read backlash on test device. Check value in

table backlash.
In case of insufficient backlash, install a
thicker shim for backlash and a thinner shim
for differential bearing rolling torque.
In case of excessive backlash, install a thinner
shim for backlash and a thicker shim for
differential bearing rolling torque.
Fig. 298
EN 4474.751.113 - 2020-10 153

Assembly
Variant with DHL-2700: Checking differential lock for tightness
46.

pressures.
Use the AA02.039.663 [Screw coupling] and

5870.286.079 [Fitting] to pressurize the lock
with compressed air p = 1.
48. Remove compressed air hose.

Fig. 299
49. Wait ten seconds.
50. Read pressure.

permissible.
If the pressure drops, disassemble the axle

housing and check the seals.
Checking contact pattern
51. Rotate input flange several times in both

directions.
52.

Remove axle housing.

5870.281.083 [Load-lifting equipment] and Fig. 300
crane.
54. Check contact pattern (refer to section

Checking contact pattern (Gleason‑gearing),
page 96).
154 EN 4474.751.113 - 2020-10

Assembly
When changing the shim, readjust the pinion

bearing rolling torque and the backlash.
Fitting shaft seal
55. Loosen slotted nut with

56. Remove washer.
Fig. 301
58. Apply grease to the inner diameter of the

shaft seal.


60. Use AA02.052.369 [Driver tool] to insert

shaft seal with sealing lip facing the oil
chamber.
In installation position in the vehicle the
marking (raised point) is at the top. Fig. 302
EN 4474.751.113 - 2020-10 155

Assembly
62. Slide on shim.
63. Apply 0666.690.022 [LOCTITE 262] onto

thread of slotted nut.
64. When tightening rotate drive pinion


65.


housing.
Fig. 304
12.2.5 Assembling and attaching axle housing
Special tools:
• 5870.204.024 Fixing pin
156 EN 4474.751.113 - 2020-10

Assembly
1. Grease O‑ring.
2. Push the O-ring (1) onto the axle housing.
Fig. 305
4.


5. Support axle housing using

5870.350.077 [Supporting bracket] and Fig. 306
5870.350.075 [Clamping fixture].
6. Fix axle housing with hexagon screws.

EN 4474.751.113 - 2020-10 157

Assembly
7. Turn in screw plug with new O‑ring and

tighten.
Fig. 307
8. Turn in screw-in sleeve and tighten.

Fig. 308
10. Insert O‑ring (1) into the annular groove of

the brake tube.
Fig. 309
158 EN 4474.751.113 - 2020-10

Assembly
11. Insert the brake tube into the axle housing.
12. Use the hexagon nut (1) and the union nut
for fixing the brake tube.
Fig. 310
12.3 Assembling and installing output and brake
12.3.1 Assembling output for variant with combined seal
Special tools:
• 5870.610.002 Insert
• 5870.506.172 Thrust collar
• 5870.051.065 Driver tool
• 5870.204.073 Eyebolt
• 5870.204.076 Eye nut

• 0666.690.044 LOCTITE 415
• 0671.090.428 WEICON® ANTI‑SEIZE AS
EN 4474.751.113 - 2020-10 159

Assembly
1. Use the tools only with hubs where

wheel studs have already been installed.
Use 5870.610.002 [Insert] and

5870.610.010 [Assembly fixture] to install the
wheel studs into the output shaft until
Fig. 311
2.

surfaces.
Heat bearing inner ring and install it onto the

output shaft until contact is obtained.

Fig. 312
5. Insert both bearing outer rings (1) into brake

Fig. 313
160 EN 4474.751.113 - 2020-10

Assembly
Installing combined seal
6. Combined seal consists of shaft seal

and cylinder liner.

surfaces.
Heat cylinder liner (inner part of the

combined seal).
7. Put cylinder liner onto collar of the output Fig. 314

shaft.
8. Use 5870.506.172 [Thrust collar] to push the

cylinder liner onto the output shaft slightly
tapping until contact is obtained.
9. Apply 0666.690.191 [PHÖNIX SPIRITUS] to

10. Insert shaft seal using 5870.051.065 [Driver

tool] into the brake housing.
Fig. 315
EN 4474.751.113 - 2020-10 161

Assembly
11. Clean sliding surfaces of the combined seal.
12. Check sliding surfaces for damage, e.g.

grooves or scratches.
13. Apply hydraulic oil according to ZF List of

Lubricants TE‑ML 05 using a lint-free cloth to
sliding surfaces.
14. Use two AA01.061.332 [Load ring] to place

the brake housing onto the output shaft until
Fig. 316
15. Insert support ring (5) into lower annular

groove.
16. Insert grooved ring (4) with sealing lip facing

upwards into lower annular groove.

downwards into upper annular groove.
18. Insert support ring (2) into upper annular

groove.
Fig. 317
19. Clean annular groove of brake housing with

0666.690.191 [PHÖNIX SPIRITUS].
20. Insert guide ring with opening showing

upwards in installation position in the vehicle.
21. Press guide ring into annular groove over

entire circumference.
22. Stick end points (1) of guide ring with

0666.690.044 [LOCTITE 415].
Fig. 318
162 EN 4474.751.113 - 2020-10

Assembly
23.

Flush-mount six slotted pins into piston holes.
Fig. 319

Lubricants TE‑ML 05 onto sliding surface of
piston, support rings, grooved rings and
guide ring.
25.

possible.
Use AA00.680.530 [Locating device] in order

to insert the piston until contact is obtained.
Fig. 320
26. Insert shim into the piston.
27. Place cup spring with convex side facing

upwards into piston.
Fig. 321
EN 4474.751.113 - 2020-10 163

Assembly
28. Insert the cover.
29. Secure the cover with hexagon screws.

Fig. 322

spare parts list.

disks.
Fig. 323
31. Position the end shim.
Fig. 324
164 EN 4474.751.113 - 2020-10

Assembly
32. Press the stop pin (1) into planetary carrier

Fig. 325
For delivery of individual parts: Assembling planetary gear


Fig. 326

2 Packaging sleeve
3 Snap ring
4 Planetary gear
EN 4474.751.113 - 2020-10 165

Assembly
35.

surfaces.
Heat up bearing inner rings of planetary

gears.
36. Slide planetary gears with large radius facing

downwards onto planetary carrier until
Fig. 327
40.

surfaces.
Heat bearing inner ring and slide it onto the

planetary carrier until contact is obtained.

Fig. 328
166 EN 4474.751.113 - 2020-10

Assembly
43. Apply 18 g
0671.090.428 [WEICON® ANTI‑SEIZE AS]
onto front face (1) of bearing inner ring and
to profile (2) of output shaft.
Fig. 329
44. Align the inner disks and outer disks centrally

and radially.
45. For variant with three planetary gears insert

planetary carrier with 5870.204.073 [Eyebolt]
and 5870.300.019 [Extracting device].
46. For variant with 4 planetary gears insert

planetary carrier with 5870.204.076 [Eye nut]
Fig. 330
Adjusting output shaft bearing
47. Insert planetary carrier using

AA00.360.730 [Measuring disk] and three
old locking screws until contact is obtained.
Fig. 331
EN 4474.751.113 - 2020-10 167

Assembly
49. Measure distance from the front face of the

output shaft to the front face of the planetary
carrier.
e. g. 0.21 mm
50. Swivel output by 90°.
51. Loosen locking screws and remove

AA00.360.730 [Measuring disk].
Fig. 332
52. Select the required cover (refer to section

Selecting the cover for adjusting the output
shaft bearing, page 98).
40_070193_01
Fig. 333
53. Insert cover with offset e.g. 0.07 mm facing

the planetary carrier.
54. Turn in new locking screws and tighten one

after the other.
55. Retighten locking screws one after the other.

Fig. 334
168 EN 4474.751.113 - 2020-10

Assembly
56. Slide new O‑ring (1) onto new cover.
Fig. 335
57. Insert the cover onto the output shaft until

Fig. 336
12.3.2 Assembling output for variant with slide ring seal
Special tools:
• 5870.610.002 Insert
• AA01.238.317 Pressure ring
• 5870.204.073 Eyebolt
• 5870.204.076 Eye nut

• 0666.690.044 LOCTITE 415
EN 4474.751.113 - 2020-10 169

Assembly
• 0671.090.428 WEICON® ANTI‑SEIZE AS
1. Use the tools only with hubs where

wheel studs have already been installed.
Use 5870.610.002 [Insert] and

5870.610.010 [Assembly fixture] to install the
wheel studs into the output shaft until
Fig. 337
2.

surfaces.
Heat bearing inner ring and install it onto the

output shaft until contact ist obtained.

Fig. 338
Installing slide ring seal
5. Carry out the following four work steps


O‑ring of new slide ring seal.

mounting bore of output shaft.
7. Put new slide ring seal (part 1) with sliding

surface facing upwards onto mounting bore
of output shaft.
Fig. 339
170 EN 4474.751.113 - 2020-10

Assembly
8. Push new slide ring seal (part 1) with a

sudden movement parallel to housing face
into output shaft using
AA01.238.317 [Pressure ring].
9. Insert both bearing outer rings (1) into brake

Fig. 340
10. Carry out the following four work steps


O‑ring of new slide ring seal.

mounting bore of brake housing.
12. Put new slide ring seal (part 2) with seal face
facing upwards onto mounting bore of brake
housing.
13. Push new slide ring seal (part 2) with a Fig. 341
sudden movement parallel to housing face
into brake housing using
AA01.238.317 [Pressure ring].
EN 4474.751.113 - 2020-10 171

Assembly
14. Clean sliding surfaces of slide ring seal.
15. Check sliding surfaces for damage, e. g.

grooves or scratches.

Lubricants TE‑ML 05 with a lint-free cloth to
sliding surfaces of slide ring seal.
17. Use two AA01.061.332 [Load ring] to place

the brake housing onto the output shaft until
Fig. 342
18. Insert support ring (5) into lower annular

groove.

upwards into lower annular groove.

downwards into upper annular groove.
21. Insert support ring (2) into upper annular

groove.
Fig. 343
22. Clean annular groove of brake housing with

0666.690.191 [PHÖNIX SPIRITUS].
23. Insert guide ring with opening showing

upwards in installation position in the vehicle.
24. Press guide ring into annular groove over

entire circumference.
25. Stick end points (1) of guide ring with

0666.690.044 [LOCTITE 415].
Fig. 344
172 EN 4474.751.113 - 2020-10

Assembly
26.

Flush-mount six slotted pins into piston holes.
Fig. 345

Lubricants TE‑ML 05 onto sliding surface of
piston, support rings, grooved rings and
guide ring.
28.

possible.
Use the AA00.680.530 [Locating device] in

order to insert the piston until contact is
Fig. 346
obtained.
29. Insert shim into the piston.
30. Place cup spring with convex side facing

upwards into piston.
Fig. 347
EN 4474.751.113 - 2020-10 173

Assembly
31. Insert cover.
32. Fasten cover with hexagon screws.

Fig. 348

spare parts list.

disks.
Fig. 349
34. Position end shim.
Fig. 350
174 EN 4474.751.113 - 2020-10

Assembly
35. Press stop pin (1) into planetary carrier until

Fig. 351
For delivery of individual parts: Assembling planetary gear


Fig. 352

2 Packaging sleeve
3 Snap ring
4 Planetary gear
EN 4474.751.113 - 2020-10 175

Assembly
38.

surfaces.
Heat up bearing inner rings of planetary

gears.
39. Slide planetary gears with large radius facing

downwards onto planetary carrier until
Fig. 353
43.

surfaces.
Heat bearing inner ring and slide it onto the

planetary carrier until contact is obtained.

Fig. 354
176 EN 4474.751.113 - 2020-10

Assembly
46. Apply 18 g
0671.090.428 [WEICON® ANTI‑SEIZE AS]
onto front face (1) of bearing inner ring and
to profile (2) of output shaft.
Fig. 355
47. Align the inner disks and outer disks centrally

and radially.
48. For variant with three planetary gears insert

planetary carrier with 5870.204.073 [Eyebolt]
49. For variant with 4 planetary gears insert

planetary carrier with 5870.204.076 [Eye nut]
Fig. 356
Adjusting output shaft bearing
50. Insert planetary carrier using

AA00.360.730 [Measuring disk] and three
old locking screws until contact is obtained.
Fig. 357
EN 4474.751.113 - 2020-10 177

Assembly
52. Measure distance from the front face of the

output shaft to the front face of the planetary
carrier.
e. g. 0.21 mm
53. Swivel output by 90°.
54. Loosen locking screws and remove

AA00.360.730 [Measuring disk].
Fig. 358
55. Select the required cover (refer to section

Selecting the cover for adjusting the output
shaft bearing, page 98).
40_070193_01
Fig. 359
56. Insert cover with offset e.g. 0.07 mm facing

the planetary carrier.
57. Turn in new locking screws and tighten one

after the other.
58. Retighten locking screws one after the other.

Fig. 360
178 EN 4474.751.113 - 2020-10

Assembly
59. Slide new O‑ring (1) onto new cover.
Fig. 361
60. Insert cover onto the output shaft until

Fig. 362
12.3.3 Mounting output
Special tools:
• 5870.204.029 Fixing pin
• AA01.395.095 Load carrying fixture
• 5870.287.007 High pressure pump
• 0501.207.939 Clutch
• 5870.950.161 Reduction
• 5870.286.072 Bottle
EN 4474.751.113 - 2020-10 179

Assembly
Adjusting axial clearance of sun gear shaft
1. Measure dimension A from mounting face of

brake housing to front face of stop pin using
depth gage, gage blocks and
5870.200.022 [Straightedge].
Distance A = e. g. 19.75 mm
Fig. 363
2. Slide stub shaft with long toothing into axle

bevel gear until contact is obtained.
Fig. 364
3. Slide sun gear shaft onto stub shaft until

Fig. 365
180 EN 4474.751.113 - 2020-10

Assembly
4. Measure distance B from mounting face of

axle housing to front face of sun gear shaft
using depth gage and
5870.200.022 [Straightedge].
Distance B = e.g. 17.15 mm
Fig. 366
5. Determine thickness s of shim ring for Axial clearance of sun gear shaft 0.5 mm to 2.0 mm.
Difference = distance A – distance B
Difference = 19.75 mm – 17.15 mm
Difference = 2.60 mm
6. Select shim ring with s = 1.2 mm or s = 2.5 mm for Axial clearance of sun gear shaft 0.5 mm to
2.0 mm.
Check axial clearance.
Axial clearance = difference – selected shim ring
Axial clearance = 2.60 mm – 1.20 mm
Axial clearance = 1.40 mm
7. Insert sun gear shaft into planetary carrier.
Fig. 367
EN 4474.751.113 - 2020-10 181

Assembly
8. Use grease to fix the selected shim ring into

sun gear shaft.
Fig. 368
9. Glue O‑ring (1) with grease into countersink

of brake housing.
Fig. 369
11. Place O‑ring (1) on axle housing.
Fig. 370
182 EN 4474.751.113 - 2020-10

Assembly
13. Use AA01.395.095 [Load carrying fixture]

and wheel nut to fasten output to crane.
14. Position output until contact with axle

housing is obtained.
15. Turn in and tighten hexagon screws.

Fig. 371
16. Turn in breather valve (1) and tighten.

Fig. 372
Checking brake hydraulics for tightness
17. Fill brake hydraulics using

5870.287.007 [High pressure pump],
0501.207.939 [Clutch],
5870.950.161 [Reduction] and
5870.286.072 [Bottle] with hydraulic oil
according to ZF List of Lubricants TE‑ML 05.
18. Bleed brake hydraulics.
19. Apply five times p = 100 bar to brake

hydraulics and open lateral shut-off valve of
5870.287.007 [High pressure pump].
20. Apply p = 100 bar to brake hydraulics and

Fig. 373
close shut-off valve on front side of
21. Wait five minutes.
EN 4474.751.113 - 2020-10 183

Assembly
22. Read pressure.
à After the waiting time, a pressure loss of

max. 2 bar is permissible.
If the pressure decreases more, disassemble

the output and check the seals.
23. Open both shut-off valves.
24. Apply p = 5 bar to brake hydraulics and close

shut-off valve on front side of
25. Wait five minutes.
26. Read pressure.

permissible.
If the pressure drops, disassemble the output

and check the seals.
12.4 Checking proper function of differential lock
Special tools:
• 5870.286.079 Fitting
1. Rotate input flange.
à One output remains stationary or the

outputs rotate in the opposite directions.
2. Turn in AA02.039.663 [Screw coupling].
3. Put on 5870.286.079 [Fitting].
4.

pressures.
Fig. 374
Apply compressed air p = 1 bar to lock.
184 EN 4474.751.113 - 2020-10

Assembly
6. Rotate input flange.
à Both outputs are rotating in the same

direction.
If outputs do not rotate in the same direction,

remove the differential and check it.
EN 4474.751.113 - 2020-10 185

Follow-up Activities
13 Follow-up Activities
13.1 Checking axle for leak tightness
Special tools:
• AA02.576.273 Connection
• 5870.286.079 Fitting
1. Replace O‑ring on screw plug (1).
2. Turn in and tighten screw plug oil drain axle

drive housing (1).
Fig. 375
3. Replace O‑rings on screw plugs (1).
4. Turn in and tighten screw plugs oil drain axle

housing (1).
Fig. 376
186 EN 4474.751.113 - 2020-10

Follow-up Activities
5. Turn in AA02.576.273 [Connection].
6. Put on 5870.286.079 [Fitting] .
7.

pressures.
Apply compressed air p = 0.4 bar to axle.

Fig. 377
9. Wait 3 minutes.
10. Read pressure.

permissible.
If the pressure drops, use leak spray to find

and repair the leak.
11. Remove 5870.286.079 [Fitting] and

AA02.576.273 [Connection] .
12. Turn in screw plug and tighten.

13.2 Filling oil
1. Prior to initial operation of the unit, fill oil according to the Operating Instructions (refer to document
overview).
EN 4474.751.113 - 2020-10 187

Annex
14 Annex
14.1 Formulary and conversion tables
14.1.1 Conversion of length units
Unit in ft yd mile n mile mm m km

1 in 1 0.08333 0.02778 — — 25.4 0.0254 —
1 ft 12 1 0.33333 — — 304.8 0.3048 —
1 yd 36 3 1 — — 914.4 0.9144 —
1 mile 63,360 5,280 1,760 1 0.86898 — 1,609.34 1.609
1 n mile 72,913 6,076.1 2,025.4 1.1508 1 — 1,852 1.852
1 mm 0.03937 3.281 • 10-3 1.094 • 10-3 — — 1 0.001 10-6
1m 39.3701 3.2808 1.0936 — — 1,000 1 0.001
1 km 39,370 3,280.8 1,093.6 0.62137 0.53996 106 1,000 1
Tab. 11 Length units
in inch ft foot
yd yard mile statute mile
n mile nautical mile
further length units:

• 1 n mile = 1 sm = 1 international nautical mile = 1 arc minute of longitude
• In Great Britain: 1 n mile (UK) = 6,080 ft » 1,853 m
• 1 Knoten = 1 n mile/h = 1.852 km/h
14.1.2 Conversion of mass units
Unit gr dram oz lb
long sh cwt long tn sh tn g kg t
cwt
Avoirdupois system (in UK and US generally used commercial weight)
1 gr 1 0.03657 0.00229 1/7,000 — — — — 0.064799 — —
1 dram 27.344 1 0.0625 0.00391 — — — — 1.77184 — —
1 oz 437.5 16 1 0.0625 — — — — 28.3495 — —
1 lb 7,000 256 16 1 0.00893 0.01 - 0.0005 453.592 0.45359 —
1 long — — — 112 1 1.12 0.05 — — 50.8023 —
cwt
1 sh — — — 100 0.8929 1 0.04464 0.05 — 45.3592 —
cwt
1 long — — — 2,240 20 22.4 1 1.12 — 1,016.05 1.01605
tn
1 sh tn — — — 2,000 17.857 20 0.8929 1 — 907.185 0.90718
SI units
1g 15.432 0.5644 0.03527 — — — — — 1 0.001 —
1 kg — — 35.274 2.2046 0.01968 0.02205 — — 1,000 1 0.001
1t — — — 2,204.6 19.684 22.046 0.9842 1.1023 106 1,000 1
Tab. 12 Mass units
gr grain oz ounze
lb pound long cwt long hundredweight
sh cwt short hundredweight long tn long ton
sh tn short ton
188 EN 4474.751.113 - 2020-10

Annex
When cwt and tn are used without long or sh in front of it, this means long cwt and long tn in the UK, cwt and sh tn in the US.
Further mass units:

• 1 slug = 14.5939 kg = mass which is accelerated by 1 ft/s² by a force of 1 lbf.
• 1 st (stone) = 14 lb = 6.35 kg (only UK)
• 1 qr (quarter) = 28 lb = 12.7006 kg (only UK, used rarely)
• 1 quintal = 100 lb = 1 sh cwt = 45.3592 kg
• 1 tdw (ton dead weight) = 1.016 t. tdw specifies the load capacity of cargo boats (load + ballast + fuel
+ food).
14.1.3 Conversion of force units
1 N = 0.101972 kp » 0.1 kgf
1 N = 0.224809 lbf
1 N = 7.233011 pdl
1 kp = 9.80665 N » 10 N
1 lbf (pound-force) = 4.44822 N
1 pdl (poundal) = 0.138255 N 1)
1 sh (sthène) = 103 N
14.1.4 Conversion of torque units
Unit Nm lb·ft
1 Nm 1 0.738
1 lb·ft 1.356 1
Tab. 13 Torque units
1) 1 pdl = Force required to accelerate a mass of 1 lb by 1 ft/s².
EN 4474.751.113 - 2020-10 189

Annex
14.1.5 Conversion of temperature units
Unit °C °F °R K
9 9
1 °C 1 °F = °C + 32 °R = °C + 491.7 K = 273 + °C
5 5
5 9
1 °F °C = (°F – 32) 1 °R = °F + 459.7 K = (°F – 32) + 273
9 5
5 9
1 °R °C = (°R – 491.7) °F = °R – 459.7 1 K= °R
9 5
9 9
1 K °C = K – 273 °F = (K – 273) + 32 °R = K 1
5 5
10_001790_02_en
Fig. 378
°C Degree Celsius °F Degree Fahrenheit
°R Degree Rankine K Kelvin
14.2 Overview of revisions
Index Date of issue Initiator comment

— 10.2020
Tab. 14 Version
190 EN 4474.751.113 - 2020-10

ZF Friedrichshafen AG
ZF Aftermarket
Donaustraße 71
94034 Passau
Deutschland · Germany
Telefon/Phone +49 851 494-0
www.zf.com/contact
EN 4474.751.113 - 2020-10

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Repair Instructions

MT‑L 3085 II, MT‑L 3095 II

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3 Notes on Repair and Assembly ................................................................................... 10

4 Technical Data ............................................................................................................ 14

6 Tightening Torques ..................................................................................................... 16

7 Workshop Equipment ................................................................................................. 18

8 Preparatory Activities .................................................................................................. 37

9 Replacing Components ............................................................................................... 39

11 Testing, Measuring, Adjusting ..................................................................................... 92

12 Assembly .................................................................................................................... 100

13 Follow-up Activities .................................................................................................... 186

13.1 Checking axle for leak tightness .................................................................................................... 186

14 Annex ......................................................................................................................... 188

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

1.1 Document overview

Document no. Denomination Technical information

2.1 Signal words and symbols

The following symbols are additionally used:

This symbol refers to additional, safety-relevant information.

2.2 General safety instructions

Installation, commissioning, maintenance and repair

Observe the following points:

Observe the following when working on the ZF product:

Observe the following when working on the ZF product:

Operating supplies and aids

Observe the following when selecting operating supplies and aids:

Observe the following when handling operating supplies and aids:

Observe the following to protect the environment:

3 Notes on Repair 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

Specialized staff assess whether parts need to be reworked.

Minor damage includes:

3.9 After Repair Work

3.9.1 Run-in behavior for slide ring seals

Damage to the slide ring seals is possible.

3. Continue driving and slowly increase the driving speed.

4.1.1 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.

The following data should be quoted when making inquiries

Fig. 1 Type plate

Designation Dimensions Measuring Comment

Designation Tightening torque Measuring Comment

• Assembling output for variant with

Designation Tightening torque Measuring Comment