VP09

Driven Front Axle
VP-09
Copy deadline 05.2004
Repair Manual
81.99198-6762 1st edition G5
MAN Nutzfahrzeuge AG Reparaturanleitung G,
Dachauer Str. 667 Angetriebene Vorderachse
80995 München VP-09
oder - Englisch -
Postfach 500620 Printed in Germany
80995 München
Repair Manual G 5
1st edition
Driven Front Axle

VP-09
81.99198-6762
PREFACE/PRINTER'S IMPRINT
PREFACE
This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units.
The technical details were correct at the time of going to press.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan
and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specifically in the text.
The repair jobs are divided up into sections and subsections. Each subsection starts with a page of jobs to
do in advance. The jobs to do in advance contain a summary of the main prerequisites for the repair section
in question. The detailed description of work can follow the jobs to do in advance.
Important instructions relating to safety and accident prevention are specially highlighted in the text as follows.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly in order to avoid
serious or irreparable damage to property.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modifications in the course of further development.
Best wishes from
MAN Nutzfahrzeuge AG
PRINTER’S IMPRINT
© 2004 MAN Nutzfahrzeuge AG
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN. All
rights under the copyright law are strictly reserved by MAN. If any changes are made without the written
approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge AG shall not be liable for any warranty or
guarantee claims arising from damage and defects attributable to the unauthorised modification. Furthermore,
MAN Nutzfahrzeuge AG shall not be liable for any damage resulting from the unapproved modification.
Redaktion: VSAID, 2W Technische Informations GmbH, MK, 05.2004
Satz: VSAID, 2W Technische Informations GmbH
Druck: MAN-Werksdruckerei
II G5
TABLE OF CONTENTS
Content Chapter/Page
Index V
Introduction
Safety regulations .................................................................................................... 1-1

Presentation of the units ............................................................................................ 1-6
Axle designation/model plate ................................................................................... 1-6
Characteristic data for VP-09 ................................................................................... 1-7
Functional description ........................................................................................... 1-8
Drum brake
Brake drum ........................................................................................................... 2 - 13

Removing and installing/repairing the brake drum ........................................................ 2 - 13
Brake shoes .......................................................................................................... 2 - 17
Removing and installing brake shoes ........................................................................ 2 - 17
Disassembling and assembling brake shoes ............................................................... 2 - 21
Diaphragm brake cylinder .......................................................................................... 2 - 27
Removing and installing the diaphragm brake cylinder ................................................... 2 - 27
Slack adjuster ........................................................................................................ 2 - 29
Removing and installing/checking the slack adjuster with indicator discs ............................. 2 - 29
Slack adjuster ........................................................................................................ 2 - 35
Removing and installing/checking the slack adjuster with brake wear sensor ....................... 2 - 35
Brake camshaft ...................................................................................................... 2 - 41
Removing and installing the brake camshaft/brake camshaft bearings ............................... 2 - 41
Backing plate ......................................................................................................... 2 - 47
Removing and installing the backing plate .................................................................. 2 - 47
Planetary hub drive
Planetary hub drive .................................................................................................. 3 - 55

Removing and installing the planetary hub drive .......................................................... 3 - 55
Disassembling and assembling the planetary hub drive ................................................. 3 - 61
Wheel hub
Wheel hub ............................................................................................................ 4 - 69

Removing and installing the wheel hub ..................................................................... 4 - 69
Disassembling and assembling the wheel hub ............................................................. 4 - 76
ABS components .................................................................................................... 4 - 87
Removing and installing the ABS components ............................................................. 4 - 87
Steering knuckle
Steering knuckle ..................................................................................................... 5 - 91

Removing and installing the steering knuckle .............................................................. 5 - 91
Steering knuckle ................................................................................................... 5 - 101
Dismantling and assembling the steering knuckle bearings ........................................... 5 - 101
Double-joint shaft
Double-joint shaft .................................................................................................. 6 - 109

Removing and installing the double-joint shaft ........................................................... 6 - 109
Axle drive
Drive shaft rotary shaft seal ..................................................................................... 7 - 119
G5 III
TABLE OF CONTENTS
Removing and installing the drive shaft rotary shaft seal .............................................. 7 - 119
Axle drive ........................................................................................................... 7 - 125
Removing and installing the axle drive .................................................................... 7 - 125
Differential .......................................................................................................... 7 - 133
Removing and installing/adjusting the differential ....................................................... 7 - 133
Dismantling and assembling the differential .............................................................. 7 - 144
Drive pinion ......................................................................................................... 7 - 155
Removing and installing/adjusting the drive pinion housing ........................................... 7 - 155
Dismantling and assembling the drive pinion housing .................................................. 7 - 159
Transverse differential lock
Transverse differential lock ...................................................................................... 8 - 173

Removing and installing the transverse differential lock ................................................ 8 - 173
Track rod/steering arm
Track rod/steering arm ............................................................................................ 9 - 181

Removing and installing the track rod/steering arm ..................................................... 9 - 181
Steering geometry ................................................................................................. 9 - 189
Camber and kingpin inclination ............................................................................. 9 - 189
Toe-in and toe-out on turns .................................................................................. 9 - 190
Preparing to set the steering geometry ........................................................................ 9 - 191
Steering geometry ............................................................................................. 9 - 191
IV G5
INDEX
Catchword Page
A
ABS components
ABS sensor .........................................................................................................................................4 - 88
Clamping sleeve..................................................................................................................................4 - 88
Pulse wheel .........................................................................................................................................4 - 80
Axle drive
Lifting device .....................................................................................................................................7 - 128
B
Backing plate
Backing plate.......................................................................................................................................2 - 49
Bearing bracket ...................................................................................................................................2 - 49
Brake camshaft/brake camshaft bearings
Inner needle bearing ...........................................................................................................................2 - 43
Outer needle bearing...........................................................................................................................2 - 43
Rotary shaft seal .................................................................................................................................2 - 44
Brake shoes
Brake shoe pin ....................................................................................................................................2 - 19
Brake shoe return spring .....................................................................................................................2 - 19
Locking plate .......................................................................................................................................2 - 19
O-ring ..................................................................................................................................................2 - 20
Plugs ...................................................................................................................................................2 - 19
D
Diaphragm brake cylinder
Adjuster screw.....................................................................................................................................2 - 28
Lock nut...............................................................................................................................................2 - 28
Differential
Backlash............................................................................................................................................7 - 139
Bearing preload .................................................................................................................................7 - 140
Bearing shell......................................................................................................................................7 - 137
Contact pattern check .......................................................................................................................7 - 142
Crown wheel......................................................................................................................................7 - 151
Differential pinion...............................................................................................................................7 - 152
Selector fork ......................................................................................................................................7 - 140
Side gear ...........................................................................................................................................7 - 151
Tapered roller bearing .......................................................................................................................7 - 139
Tapered roller bearing (crown wheel side) ........................................................................................7 - 150
Tapered roller bearing (differential side) ............................................................................................7 - 150
Threaded ring ....................................................................................................................................7 - 137
Drive pinion
Drive pinion housing installation depth..............................................................................................7 - 158
Drive pinion installation dimension ....................................................................................................7 - 166
Fitted washer.....................................................................................................................................7 - 166
Friction coefficient .............................................................................................................................7 - 168
Inner bearing outer race ....................................................................................................................7 - 164
Oil baffle ............................................................................................................................................7 - 164
Outer bearing outer race ...................................................................................................................7 - 164
Sealing ring .......................................................................................................................................7 - 157
Shim ..................................................................................................................................................7 - 157
Drive shaft
Bi-hexagonal nut ...............................................................................................................................7 - 122
Input flange........................................................................................................................................7 - 122
Rotary shaft seal ...............................................................................................................................7 - 122
P
Planetary hub drive
Bearing needles ..................................................................................................................................3 - 65
Bell hub cover......................................................................................................................................3 - 57
G5 V
INDEX
Fitted collar bolt ...................................................................................................................................3 - 63

Mounting bolts .....................................................................................................................................3 - 57
O-ring ..................................................................................................................................................3 - 58
Planet gear shaft .................................................................................................................................3 - 64
Planet gear thrust washer ...................................................................................................................3 - 65
Planet gears ........................................................................................................................................3 - 65
Ring gear.............................................................................................................................................3 - 63
Sun gear..............................................................................................................................................3 - 58
Supporting ring ....................................................................................................................................3 - 57
Thrust washer......................................................................................................................................3 - 57
S
Safety regulations.......................................................................................................................................1 - 1
General..................................................................................................................................................1 - 1
Slack adjuster
Brake wear sensor ..............................................................................................................................2 - 36
Control arm..........................................................................................................................................2 - 37
End disc...............................................................................................................................................2 - 30
Indicator disc .......................................................................................................................................2 - 30
Slip clutch ............................................................................................................................................2 - 30
Steering geometry/explanation
Camber..................................................................................................................................................1 - 9
Caster....................................................................................................................................................1 - 9
Kingpin inclination .................................................................................................................................1 - 9
Toe-in.....................................................................................................................................................1 - 9
Toe-out ..................................................................................................................................................1 - 9
Toe-out on turns ....................................................................................................................................1 - 9
Steering knuckle
Rotary shaft seal, cover.....................................................................................................................5 - 104
Rotary shaft seal, steering knuckle arm ............................................................................................5 - 103
T
Technical data
Camber..............................................................................................................................................9 - 189
Kingpin inclination .............................................................................................................................9 - 189
Technical data for brake drum .............................................................................................................2 - 13
Technical data for brake shoes............................................................................................................2 - 21
Toe-in.................................................................................................................................................9 - 190
Toe-out on turns ................................................................................................................................9 - 190
Transverse differential lock
Axial play ...........................................................................................................................................8 - 178
Bearing bush .....................................................................................................................................8 - 176
O-ring ................................................................................................................................................8 - 177
Selector cylinder cover ......................................................................................................................8 - 176
Selector fork ......................................................................................................................................8 - 177
Selector shaft ....................................................................................................................................8 - 176
Sliding sleeve ....................................................................................................................................8 - 176
W
Wheel hub
Grooved nut.........................................................................................................................................4 - 72
Inner bearing outer race ......................................................................................................................4 - 79
Inner rotary shaft seal..........................................................................................................................4 - 82
Inner tapered roller bearing .................................................................................................................4 - 72
Outer bearing outer race .....................................................................................................................4 - 80
Outer rotary shaft seal.........................................................................................................................4 - 83
Race ....................................................................................................................................................4 - 73
Retainer...............................................................................................................................................4 - 72
Wheel bolt ...........................................................................................................................................4 - 84
VI G5
INTRODUCTION
INTRODUCTION
SAFETY REGULATIONS
General
Working with trucks, buses and the necessary service products does not pose any problems provided the
people entrusted with operation, maintenance and repair have been trained accordingly and actively keep
their minds on the job.
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. They represent only a small excerpt from the wide range of accident prevention
regulations and cannot replace these. It goes without saying that all other safety regulations must be
followed and that the corresponding action must be taken.
Additional direct references to danger are contained in the instructions at points where there is a potential
danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
etc.
1. Regulations for preventing accidents leading to injury to personnel
Secure units during their removal.

Support the frame when working on the pneumatic or spring suspension system.
Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
Accidents caused by slipping can have very serious consequences.
Only authorised technical personnel are entitled to perform inspection,
adjustment and repair work
Working on the brake system

Perform visual, function and effectiveness checks on the brake system after carrying
out any work on it whatsoever. These checks must be made in accordance with the
safety inspection (SP).
Check the function of ABS/ASR systems using a suitable test system (e.g.
MAN-cats).
Collect hydraulic oil and brake fluid as it drains out.
Hydraulic oil/brake fluid is poisonous!
Do not allow brake fluid to come into contact with food or open wounds.
Treat hydraulic oil/brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
G5 1-1
INTRODUCTION
Engine operation
Only authorised personnel are permitted to start and operate an engine.
Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.
Ensure adequate ventilation if you are working in enclosed spaces.
Do not touch units with your bare hands when they are at operating temperature.
Danger of burns!
Always wear protective gloves when changing oil (in units at operating temperature)
in particular.
Do not open the coolant circuit unless the engine is cool.
Suspended loads
No-one is allowed to stand under a unit suspended from a crane hook. - Keep all
lifting tackle in good condition -
Working on high-pressure lines

Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit).
Fluid spraying out represents an injury hazard!
Do not hold your hands under the jet of fuel when checking the injector nozzles. Do
not inhale fuel vapours.
Working on the vehicle electrical system

Always disconnect the batteries before working on the electrical system.
Disconnect the earth cable first and connect it last when reconnecting.
Important! Battery gases are explosive!
Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after
long journeys and after charging the batteries with a battery charger.
When the batteries are disconnected this gas may be ignited by sparks produced
by other continuously operating consumers, the tachograph etc. that cannot be
shut down. Blow compressed air through the battery box before disconnecting the
batteries!
Tow-start the vehicle only with the batteries connected (minimum charge 40%)!
Do not use a boost-charger to jump-start the vehicle! Disconnect the positive and
negative leads before boost-charging batteries!
Avoid short circuits caused by polarity reversal or by placing metal objects (spanners,
mole grips, etc.) on the battery terminals.
Disconnect the batteries or recharge them every 4 weeks if the vehicle is not in use.
Caution! Battery acid is poisonous and corrosive!

Wear appropriate protective clothing (gloves) when handling batteries.
Do not tilt batteries, acid may leak out.
Measure voltage only using a suitable measurement device! The input resistance of
the measurement device must be at least 10 MΩ.
The ignition must be switched off before the wiring harness plugs of the electronic
control units are disconnected or connected up!
1-2 G5
INTRODUCTION
Electric welding
Connect up the "ANTIZAP SERVICE MONITOR" protective device (MAN item
number 80.78010.0002) in accordance with the instructions supplied with the device.
If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a conductive connection.
Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
The chassis is not intended for use as an earth return. If attachments are to be fitted
to the vehicle (e.g. a wheelchair lift), additional earth (ground) lines with an adequate
cross-section must be fitted as well. Otherwise the earth connection may be created
along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe damage
could result.
Working on polyamide tubes - danger of damage and fire!

The warning sign opposite is attached to the inside of the diesel fuel or heating oil
tank flap. It warns you against welding or drilling near to plastic tubes.
Painting
If paint spraying is to be carried out, do not expose the electronic components to
high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours
is permissible at a maximum of 85 °C. Disconnect the batteries.
Working whilst the cab is tilted

Keep the tilting area in front of the cab clear.
Keep out of the area between the cab and the chassis during the tilting process. This
is a danger area!
Always tilt the cab past the tilting point to its final position
Working on the air-conditioning system

Coolant fluids and vapours represent a health hazard, avoid contact with them and
protect your eyes and hands.
Do not drain gaseous coolants in enclosed rooms.
Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
2. Notes on preventing damage and premature wear on units

Only subject units to the load which they have been designed to cope with in accordance with their
designated use. Do not overload them.
If a fault occurs during operation, determine its cause immediately and correct the problem before the fault
can get any worse.
Clean the units thoroughly before repairs. Ensure that no dirt, sand or foreign objects can get into the units
whilst carrying out repairs.
Always use genuine parts. Fitting "equivalent parts" made by other companies can lead to severe damage,
and the workshop that did the work will be responsible for it. See the section entitled "Limited liability for
accessories and parts".
Never run a unit dry, in other words always make sure that it has been filled with oil before running it.
Never run engines without coolant.
Apply a suitable information sign to units that are not ready to be operated.
G5 1-3
INTRODUCTION
Only use service products (engine and gearbox oil as well as antifreeze and anti-corrosion protection) that
have been approved by MAN. Keep your workplace clean.
Comply with the specified maintenance intervals.
Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
Severe damage to the unit could result from failure to follow these regulations.
3. Limited liability for accessories and parts

In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts. The reliability, safety and suitability of these parts and accessories have been determined
specifically for MAN vehicles. Despite constant market observation, we cannot judge the aspects of other
products, nor can we accept responsibility for them – even if they have been officially approved by the German
TÜV technical inspection authorities or some other official body.
Attachments and special bodies

Comply with the safety instructions and regulations issued by the body builder in question if attachments or
special bodies have been fitted.
Taking out of operation or putting into storage

The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
withdrawn from service or stored for a period longer than 3 months.
4. Handling brake pads and similar components

Harmful dust may be released when brake pads are machined, in particular during skimming and grinding
as well as when wheel brakes are blown out.
Please take the necessary precautionary measures and observe the following safety advice to avoid
possible damage to your health:
If possible, carry out the work in question in the open or in an area equipped with an efficient ventilation
system.
If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required.
Fast-running tools should always be fitted with such a device.
If possible, wet the workpiece prior to cutting or drilling.
Dispose of brake pads or linings as hazardous waste in an environmentally sound manner.
5. Regulations for avoiding injury and environmental contamination
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by specific local
regulations. However, the cleaning fluid and rinsing water must in all cases have been passed through an oil
trap with a sludge trap.
Cleaning the filter element

When blowing compressed air through the filter element, make sure the filter dust is collected by a vacuum
or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber gloves or
use a skin barrier hand cream when washing out the elements, because cleaning agents have aggressive
grease-dissolving characteristics.
Engine/gear oil, filter cartridges, elements and box-type filters, desiccant cartridges
Only dispose of used oil at an approved collection point or depot. It is extremely important that oil is not
poured down the drain or onto the ground since it can pollute drinking water! Filter elements, cartridges and
box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are classified as hazardous waste
materials and must be disposed of properly. Please follow the instructions of your relevant local authority.
Used engine/gear oil

Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can
cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains dangerous
materials which have been shown to have a carcinogenic effect in animal skin tests.
1-4 G5
INTRODUCTION
6. Health protection precautions

Avoid lengthy, excessive or repeated skin contact with used oils.
Protect your skin using a suitable skin protection agent or protective gloves.
Clean areas of skin which have come into contact with engine oil.
Wash the areas thoroughly with soap and water.
A nail brush enables more effective cleaning.
Special cleaning agents make it easier to clean dirty hands.
Do not use petrol, diesel oil, gas oil, thinners or solvents.
Apply a greasy skin cream after cleaning your skin.
Change out of clothing or shoes which have become soaked with oil.
Never put oil-soaked rags into your clothing pockets.
Take care to dispose of used engine/gear oil properly.
- Oils can damage groundwater quality -
Therefore, never pour used oil onto the ground, into water or down the drains or sewers. Failure to comply
with these instructions can lead to prosecution.
Collect and dispose of used oil carefully. Contact the point of sale, supplier or your local authority for
information about collection depots.
Extract from "Information on dealing with used engine oil"
The Mineral Oil Traders’ Association (MINERALÖLWIRTSCHAFTSVERBAND E.V.) Steindamm 71, D-20099
Hamburg
G5 1-5
INTRODUCTION
PRESENTATION OF THE UNITS
Axle designation/model plate
Model plate
(1) Position of model plate on axle drive
Explanation of model plate for VP-09
I= Number of teeth on crown wheel/drive pinion and planetary reduction ratio

FZ = Axle drive serial number
NR. = MAN axle drive item number
TYP = Axle type and variant
FZ = Serial number for complete axle
Classification Classification terms Explanation

no.
VP Axle type/drive Front axle with planetary hub drive
09 Load rating/in t in the case of driven axles 9 tonnes
03 Variant/version
1-6 G5
INTRODUCTION
Characteristic data for VP-09
VP-09-04
Designation Unit Version

Brake type S-cam brake with automatic adjustment
Brake drum diameter mm 410
Brake lining width mm 160
Axle weight with differential lock kg approx. 738
Axle drive oil fill quantity l 6
Planetary hub drive oil fill quantity l 2 x 1.5
Steering knuckle oil fill quantity l 4 x 0.05
Planetary hub drive ratio ip 3.0
Distance between spring centres mm 880
VP-09-05

VP-09-06 (for 525/65 R20.5 tyres only)

G5 1-7
INTRODUCTION
Functional description
(1) Steering knuckle arm (6) Planetary hub drive

(2) Brake drum (7) Axle housing
(3) Diaphragm brake cylinder (8) Axle drive
(4) Steering arm (9) Track rod
(5) Bearing bracket
Reduction ratios/calculations for gear drive

The VP-09 driven front axle is a planetary axle with straight-cut planetary hub drive.
1. Reduction via the axle drive = i-bevel drive (ik) (number of crown wheel teeth/number of drive pinion teeth).
2. Reduction via the planetary hub drive = i-planet (ip).
The reduction ratio (ik) is the number of teeth on the driven wheel (Z1) divided by the number of teeth on the
driving wheel (Z2).
The total reduction ratio (i-total) is the reduction ratio i-planet (ip) multiplied by i-bevel drive (ik).
Example: i-total = 3.00 (ip) x 1.083 (ik) = 3.250
Reduction ratios for the VP-09 axle
i-planet i-bevel drive i-total

3.00 1.083 3.250
3.00 1.208 3.625
3.00 1.333 4.000
1-8 G5
INTRODUCTION
4.00 1.083 4.333

4.00 1.208 4.833
4.00 1.333 5.333
4.00 1.500 6.000
4.00 1.706 6.824
VP-09
Functional description
The VP 09 axle described is a driven, steering planetary axle without through-drive and straight-cut planetary
drive. The axle has two reduction stages:
1. Reduction via the axle drive = ik (number of crown wheel teeth/number of drive pinion teeth).
2. Reduction via the planetary hub drive = ip
The power arriving from the vehicle gearbox flows to the driven axle input flange via the propshafts.
Axle drive
The axle drive consists of the gear set (drive pinion/crown wheel) and the differential. The differential function
is provided by a differential spider made up of pins. The axle drive input flange has cross serrations.
Wheel hub
The oil-lubricated wheel hub is supported in two tapered roller bearings. The wheel hub is sealed by two
rotary shaft seals which differ by virtue of their number of sealing lips.
Wheel brake
The brake is a compressed air-operated drum brake with automatic adjustment and a continuous mechanical
wear indicator. An electronic wear indicator (brake wear sensor) is available as special equipment. It is
actuated by compressed air/mechanically by means of diaphragm brake cylinder. Transmission to the brake
shoes is via brake camshafts. The automatic adjustment feature takes effect depending on the degree of
wear and operates with a fixed clearance.
A checking device informs the driver when the asbestos-free brake linings reach their wear limit.
The diaphragm brake cylinders are mounted on the brake camshaft bearing brackets.
Steering geometry
Camber is the angle formed between the wheel centre plane and the vertical. A distinction is made between
positive and negative camber. If the wheel centre plane tilts outwards at the top, the camber is positive. If the
wheel centre plane tilts inwards at the top, the camber is negative.
The kingpin inclination is the angle formed between the kingpin axis and the vertical. It cannot be adjusted.
Caster is the angle between the kingpin axis and the centre line of the wheel as viewed from the side. The
caster values assume a frame position of 0°. If the frame is inclined forwards, this angle (in degrees) must
be added to the caster. If the frame is inclined rearwards, this value must be subtracted from the caster.
The toe-out on turns is the steering axle difference between the inner and outer wheels on the steering axle.
The toe-out on turns is determined when a wheel has a steering angle of 20°. The steering angle measured
on the other wheel is subtracted from 20°. The difference is the toe-out on turns. This measurement must
be repeated for the other side. The toe-out on turns has to be measured in order to detect possible steering
transmission part damage or deformation.
Toe-in is the degree by which the wheels on a given axle are closer together at the front than they are at the
back. Toe-out is the degree by which the wheels on a given axle are further apart at the front than they are
at the back.
G5 1-9
DRUM BRAKE
DRUM BRAKE
(1) Brake shoe with brake lining (10) Brake camshaft bearing
(2) Diaphragm brake cylinder (11) Brake camshaft
(3) Circlip (12) Brake drum
(4) Shim (13) Mounting bolts for backing plate
(5) Brake wear sensor (special equipment) (14) Brake shoe return spring
(6) Slack adjuster (15) Brake shoe with brake lining
(7) Bearing bracket (16) Brake shoe pin
(8) Mounting bolt for bearing bracket (17) Backing plate
(9) Rotary shaft seal (18) Cover plate
G5 2 - 11
DRUM BRAKE
BRAKE DRUM
Removing and installing/repairing the brake drum
Includes
Jacking points, see Operator’s Manual
Supporting the vehicle using support blocks
Removing and fitting wheels, see Operator’s Manual
(1) Cover plate (3) Bell hub

(2) Brake shoe with brake lining (4) Brake drum
Technical data
Brake shoe clearance measured in centre of brake shoe (2) ................................................... 0.7+ 0.3 mm
Minimum brake lining thickness ................................................................................................5.0-5.5 mm
Loosening torque for the slack adjuster adjusting screw............................................................ min. 18 Nm
Brake drum repair levels

Inside diameter of brake drum (4) .............................................................................................410.00 mm
Normal dimension of brake drum (4)............................................................................. 410.00-410.20 mm
Wear limit............................................................................................................................ max. 414 mm
Important information
Note
Perform visual, function and effectiveness checks on the brake system after carrying out any work
on it whatsoever. These checks must be made in accordance with the valid brake inspection
directives.
G5 2 - 13
DRUM BRAKE
Special tools
[1] Puller screw 06.01734-4320
• Removing the brake drum
[2] Clamping device 80.99614-0008
• Repairing the brake drum
[3] Feeler gauge 08.75310-0806
• Checking the clearance
2 - 14 G5
DRUM BRAKE
Removing the brake drum Repairing the brake drum
Moving back the wheel brake
Note
Note the maximum skimming size (A) or
Note wear limit of max. 414 mm .
When resetting at the slack adjuster Always skim brake drums on the same
adjusting screw (1), a loosening torque axle to the same size.
of min. 18 Nm must be reached. Skim the brake drum with the larger inside
If this loosening torque is not reached, the diameter first.
slack adjuster is defective and needs to After renewing or skimming the brake
be exchanged. drum, it may be necessary to adapt
the brake linings to suit the new inside
• Move back the brake camshaft by turning the diameter of the brake drum.
adjusting screw (1) anticlockwise
• Fit the Clamping device [2] into the brake drum
Removing the brake drum • Use the Clamping device [2] to clamp the brake
drum in a lathe and skim both brake drums to the
same size (A)
• After skimming, check the brake drum for errors.
Renew the brake drum if necessary
• Mark the position of the brake drum (2) relative to

the bell hub (1)
• Evenly press off the brake drum (2) using the
Puller screw [1] (3)
• Remove the brake drum (2)
• Unscrew the Puller screw [1]
• Check the brake drum (2) for score marks, cracks
and unevenness
• Skim the brake drum or, if necessary, renew it
G5 2 - 15
DRUM BRAKE
Installing the brake drum
Mounting the brake drum
• Align the brake drum (1) with the bell hub as

marked
• Mount the brake drum (1) and push it on as far as
the stop
Checking the clearance
• Use the Feeler gauge [3] (1) to check that the

clearance is 0.7+ 0.3 mm
• If necessary, correct the clearance by turning the
adjusting screw on the slack adjuster
• Turn the wheel hub with brake drum several times
and check the brake drum for ease of movement
If the brake drum does not move freely, repeat the
entire operation
2 - 16 G5
DRUM BRAKE
BRAKE SHOES
Removing and installing brake shoes
Includes
Removing and installing/repairing the brake drum, see 2-13
(1) Brake shoe with brake lining (4) Locking plate

(2) Brake shoe return springs (5) Brake shoe pin
(3) Hexagon locking bolt for locking plate
Technical data
Hexagon locking bolt for locking plate (3) ............... M10x16-8.8 ................................................. 40 ± 5 Nm
Service products
MAN 284 Li-H2 high-temperature grease ............................................................................ 09.15006-0001
Note
To illustrate the work involved when removing and installing brake shoes more clearly, the wheel
hub has been omitted from the diagrams.
The work can also be performed with the wheel hub mounted.
G5 2 - 17
DRUM BRAKE
Special tools
[4] Assembly lever 80.99606-6003
• Removing and installing brake shoe return

springs
2 - 18 G5
DRUM BRAKE
Removing brake shoes Removing the plugs
Removing the front brake shoe return spring
• Remove both plugs (1) from the cover plate (2)
• Remove the front return spring (1) using the Removing brake shoes
Assembly lever [4] (2)
Removing the rear brake shoe return spring
• Remove the rear return spring (2) using the

Removing the locking plate
• Insert the drive tool through the opening in the

cover plate
• Knock out both brake shoe pins (4)
• Remove both brake shoes (1)
• Remove the O-rings (2) and (3) from the brake
shoe eyes
• Unscrew the mounting bolt (2)

• Remove the locking plate (1)
G5 2 - 19
DRUM BRAKE
Installing brake shoes Installing the rear brake shoe return spring
• Install the rear return spring (2) using the

Installing the front brake shoe return spring
• Insert new O-rings (2) and (3) into the brake shoe
eyes
• Apply MAN 284 Li-H2 high-temperature grease on
the bush for the brake shoe pins
• Insert the brake shoe (1) into the backing plate
• Locate the groove of the brake shoe pin (4) so that • Install the front return spring (1) using the
the locking plate can be inserted later Assembly lever [4] (2)
• Knock in the brake shoe pins (4)
• Repeat the procedure for the second brake shoe Installing the plugs
Installing the locking plate
• Install both plugs (1) in the cover plate (2)
• Insert the locking plate (1) into the brake shoe pin
groove
• Screw in the hexagon locking bolt (2) and tighten
it to 40 ± 5 Nm
2 - 20 G5
DRUM BRAKE
Disassembling and assembling brake shoes
Includes
Removing and installing brake shoes, see 2-17
(1) Sealing ring (5) Washer

(2) Bushing for brake shoe pin (6) Circlip
(3) Pin for brake shoe roller (7) Spring retaining pin
(4) Brake shoe roller (8) Brake shoe
Technical data
Brake lining thickness for cam brake with brake drum inside Ø 410 mm .............................................
Normal............................................................................................................................... 18.0 + 0.3 mm
Minimum size following repairs ............................................................................................ 16.7 + 0.3 mm
Repair level I ...................................................................................................................... 18.8 + 0.3 mm
Repair level II ..................................................................................................................... 19.5 + 0.3 mm
Height of wear edges (minimum lining thickness)

Normal.................................................................................................................................5.0 + 0.5 mm
Minimum size following repairs ..............................................................................................5.0 + 0.5 mm
Repair level I ........................................................................................................................6.0 + 0.5 mm
Repair level II .......................................................................................................................7.0 + 0.5 mm
Riveting force
Preload force...................................................................................................................................300 N
Riveting force ............................................................................................................................. 20,000 N
Service products
G5 2 - 21
DRUM BRAKE
Note
Replace all the brake linings on the axle in question, not just those on one side.
On each axle, only use approved brake linings that are of the same quality and made by the same
manufacturer.
Dispose of used brake linings as hazardous waste.
Perform visual, function and effectiveness checks on the brake system after carrying out any work
on it whatsoever. These checks must be made in accordance with the valid brake inspection
directives.
Special tools
[5] Pressing tool 80.99617-0010
• Removing and installing bushings for brake shoe

pins
[6] Clamping device 80.99606-0014
• Skimming brake linings
2 - 22 G5
DRUM BRAKE
Renewing the brake lining Riveting on the brake lining
Removing the brake lining
CAUTION
Risk of serious damage to health due
to swirled-up brake dust
• Wear a breathing mask
• Do not used compressed air to clean
the brake shoe
• Remove the rivets (3) from the brake lining

sections
• Remove the brake lining (1)
• Clean the brake shoe (2)
WARNING
The brake lining does not lie evenly on
the brake shoe
• Always rivet the brake lining from the
centre of the brake lining outwards
• Carry out riveting crosswise
• Place the brake lining on the brake shoe with the

thicker side facing the centre of the brake shoe
• Attach the brake lining using 2 rivets (1) and (4)
• Use the clamping device to press the brake shoe
and brake lining together by applying a preload
force "A" of 300 N . Keep this preload force applied
until riveting is complete
• Rivet on the brake lining by applying the riveting
force (B) 20,000 N , starting with rivets (2) and (3)
G5 2 - 23
DRUM BRAKE
Skimming brake linings Renewing the bushing for the brake shoe pin
Removing the bushing for the brake shoe pin
Note
Skim the brake linings until the brake
lining outside diameter (dimension "B")
is always 1 mm less than the brake drum
inside diameter.
Do not let the brake lining thickness fall
below the minimum permitted size of 5.0
+ 0.5 mm .
• Clamp the brake shoe on Clamping device [6]

and then skim the brake linings to the correct size
(dimension "B")
• Clean the brake shoes
• Remove both sealing rings (1) from the brake shoe

eye
• Remove the bushing for the brake shoe pin (2)
from the brake shoe eye using Pressing tool [5]
2 - 24 G5
DRUM BRAKE
Inserting the bushing for the brake shoe pin Renewing the brake shoe roller
Removing the brake shoe roller
Note
The press-in depth for the brake shoe • Detach the circlip (1) from the pin for the brake
pin bushing is determined by the spacing shoe roller (3) and remove it together with the
ring. washer
• Knock out the pin (2) for the brake shoe roller (3)
• Fit the new bushing for the brake shoe pin (2) and remove the brake shoe roller (3)
dry using Pressing tool [5] and the accompanying
spacing ring
• Insert new sealing rings (1) into the brake shoe
eyes
the bushing for the brake shoe pin (2)
G5 2 - 25
DRUM BRAKE
Installing the brake shoe roller
• Insert the brake shoe roller (3) into the brake shoe
• Insert the pin (2) for the brake shoe roller (3)
• Fit the washer and attach the circlip (1) in the pin
(2) for the brake shoe roller (3)
2 - 26 G5
DRUM BRAKE
DIAPHRAGM BRAKE CYLINDER
Removing and installing the diaphragm brake cylinder
(1) Diaphragm brake cylinder lock nut (3) Diaphragm brake cylinder
(2) Split pin (4) Cotter pin
Technical data
Diaphragm brake cylinder lock nut (1).................... M16x1.5 .................................................. 190 ± 20 Nm
Brake line tightening torque.............................................................................................................81 Nm
G5 2 - 27
DRUM BRAKE
Removing the diaphragm brake cylinder Installing the diaphragm brake cylinder
Removing the cotter pin
Note
• Release and remove the split pin (1) Use new lock nuts.
• Knock out the cotter pin (2)
Removing the diaphragm brake cylinder • Position the diaphragm brake cylinder (3)
• Screw on the lock nuts (2) and tighten them to
190 ± 20 Nm
• Attach the brake line to the diaphragm brake
cylinder (3) and tighten it to 81 Nm
• Turn the slack adjuster (1) by turning the adjuster
screw (4) towards the diaphragm brake cylinder
(3) until the holes in the yoke of the diaphragm
brake cylinder (3) and the slack adjuster (1) are
aligned
Installing the cotter pin
• Detach the brake line at the diaphragm brake

cylinder (3)
• Turn away the slack adjuster (1) by turning the
adjuster screw (4) away from the diaphragm brake
cylinder (3)
• Unscrew the lock nuts (2)
• Remove the diaphragm brake cylinder (3)
• Change the compressed air connection
• Insert the cotter pin (2)

• Insert and lock the split pin (1) in the cotter pin (2)
2 - 28 G5
DRUM BRAKE
SLACK ADJUSTER
Removing and installing/checking the slack adjuster with indicator discs
(1) Split pin (7) Control arm mounting bolt

(2) Cotter pin (8) Brake camshaft
(3) Circlip (9) Control arm
(4) End disc (10) Slack adjuster
(5) Shim (11) Spacer washer
(6) Indicator disc
Technical data
Control arm mounting bolt (7) ................................ M8x12-8.8 .........................................................22 Nm
Loosening torque for the slack adjuster adjusting screw (10)..................................................... min. 18 Nm
Minimum brake lining thickness ..................................................................................................... 5.0 mm
Brake shoe clearance measured in centre of brake shoe ........................................................ 0.7+ 0.3 mm
Shim thickness sizes

Thickness of shims (5) ............................................................................................ 3.5/4.0/4.5/5.0/5.5 mm
Maximum permitted axial play on brake camshaft (8)................................................................... 0.5-1 mm
G5 2 - 29
DRUM BRAKE
Checking the slack adjuster Removing the slack adjuster
Checking for wear Removing the indicator disc
• Detach the circlip (5) from the groove in the brake

Note
camshaft (1)
The only way to check the wear
• Remove the end disc (4) and the shim (3) from the
accurately is through the inspection
brake camshaft (1)
holes in the cover plates.
• Remove the indicator disc (2) from the brake
Minimum lining thickness: 5.0 mm .
camshaft (1)
• Check the brake lining wear on the slack adjuster Removing the cotter pin
If the brake linings have reached their wear limit,
the pointer (2) on the indicator disc is pointing to the
slack adjuster check mark (1)
Checking the slack adjuster slip clutch
• Release and remove the split pin (2)

• Unscrew the control arm mounting bolt (4)
• Turn away the slack adjuster (1) by turning the
adjuster screw (5) away from the diaphragm brake
Note cylinder
When resetting at the slack adjuster
adjusting screw (1), a loosening torque
of min. 18 Nm must be reached.
If this loosening torque is not reached, the
slack adjuster is defective and needs to
be exchanged.
• Apply min. 18 Nm in anticlockwise direction on the

slack adjuster adjusting screw (1). The adjusting
screw (1) must not turn
2 - 30 G5
DRUM BRAKE
Removing the slack adjuster Mounting the slack adjuster
• Pull the slack adjuster (3) with spacer washer (2) • Place the stepped side of the spacer washer (2)
off the brake camshaft (1) onto the brake camshaft (1)
• Fit the slack adjuster (3) onto the brake camshaft
so that the bore for the cotter pin is in front of the
diaphragm brake cylinder yoke

until the holes in the yoke (4) and the slack adjuster
(2) are aligned
• Insert the cotter pin (5) and secure using a new
split pin (3)
• Screw in the control arm mounting bolt (6) and
tighten it by hand
• Turn the control arm in the rotation direction of
the slack adjuster (1) (direction arrow on slack
adjuster) until the stop is reached and tighten the
mounting bolt (6) to 22 Nm
G5 2 - 31
DRUM BRAKE
Installing the indicator disc Checking the slack adjuster
Checking the slack adjuster setting
Note
Shims (3) are available in thickness sizes • Release and remove the cotter pin (1)
of 3.5/4.0/4.5/5.0/5.5 mm . • Press the slack adjuster towards the diaphragm
brake cylinder. The slack adjuster must not give
• Fit the indicator disc (2) with the notch facing the • Screw in the control arm mounting bolt (2) and
mark on the slack adjuster (1) tighten it to 22 Nm
• Fit the shim (3) and the end disc (4) • Insert the cotter pin (1) and secure using a new
• Attach a new circlip (5) in the brake camshaft split pin
groove
• Check the brake camshaft end play
• The maximum permitted axial play is 0.5-1 mm
• Adjust the axial play using suitable shims
2 - 32 G5
DRUM BRAKE
Basic slack adjuster setting
Turning back the adjusting screw
• Use a ring spanner to turn the adjusting screw (1)

on the slack adjuster in the direction indicated by
the arrow until the brake linings contact the brake
drum
• Turn back the adjusting screw on the slack
adjuster (in the opposite direction to the arrow) by
approx. 270°
Checking the adjustment
• Check the slack adjuster adjustment function by

operating the service brake system several times
The adjusting screw with attached ring spanner must
move gradually until the clearance of 0.7+ 0.3 mm
is reached
G5 2 - 33
DRUM BRAKE
SLACK ADJUSTER
Removing and installing/checking the slack adjuster with brake wear sensor
(1) Split pin (7) Brake wear sensor

(2) Bearing bracket (8) Brake camshaft
(3) Cotter pin (9) Control arm
(4) Control arm mounting bolt (10) Slack adjuster
(5) Circlip (11) Slack adjuster adjusting screw
(6) Shim (12) Spacer washer
Technical data
Control arm mounting bolt (4) ................................ M8x12-8.8 .........................................................22 Nm
Loosening torque for the slack adjuster adjusting screw (10)..................................................... min. 18 Nm
Brake shoe clearance measured in centre of brake shoe .........................................................0.7+ 0.3 mm
Shim thickness sizes

Thickness of shims (6) ............................................................................................ 3.5/4.0/4.5/5.0/5.5 mm
Maximum permitted axial play on brake camshaft (8)................................................................... 0.5-1 mm
Mounting bolt for brake wear sensor (7) .................................................................................... 3 ± 0.3 Nm
G5 2 - 35
DRUM BRAKE
Checking the slack adjuster Removing the slack adjuster
Checking the slack adjuster slip clutch Removing the cotter pin
• Release and remove the split pin (1)

Note
When resetting at the slack adjuster
• Unscrew the control arm mounting bolt (3)
adjusting screw (1), a loosening torque
• Turn away the slack adjuster by turning the
of min. 18 Nm must be reached.
adjuster screw (4) away from the diaphragm
If this loosening torque is not reached, the
brake cylinder
slack adjuster is defective and needs to
be exchanged. Removing the brake wear sensor
• Apply min. 18 Nm in anticlockwise direction on the
slack adjuster adjusting screw (1). The adjusting
screw (1) must not turn
• Detach the circlip (4) from the groove in the brake

camshaft (1)
• Remove the shim (3) from the brake camshaft (1)
• Remove the brake wear sensor (2) from the brake
camshaft (1)
2 - 36 G5
DRUM BRAKE
Removing the slack adjuster Mounting the slack adjuster
• Pull the slack adjuster (3) with shim (2) off the • Place the stepped side of the shim (2) onto the
brake camshaft (1) brake camshaft (1)
• Fit the slack adjuster (3) onto the brake camshaft
so that the bore for the cotter pin is in front of the
diaphragm brake cylinder yoke

until the holes in the yoke (4) and the slack adjuster
(2) are aligned
• Insert the cotter pin (5) and secure using a new
split pin
• Screw in the control arm mounting bolt (6) and
tighten it by hand
• Turn the control arm in the rotation direction of
the slack adjuster (1) (direction arrow on slack
adjuster) until the stop is reached and tighten the
mounting bolt (6) to 22 Nm
G5 2 - 37
DRUM BRAKE
Installing the brake wear sensor Checking the slack adjuster
Checking the slack adjuster setting
Note
Shims (3) are available in thickness sizes • Release and remove the split pin
of 3.5/4.0/4.5/5.0/5.5 mm . • Knock out the cotter pin (1)
• Press the slack adjuster towards the diaphragm
• Transfer the mark (1) on the inside of the brake brake cylinder. The slack adjuster must not give
wear sensor (2) to the outside • If the slack adjuster gives, repeat the adjustment
• Align the mark on the brake wear sensor (2) with procedure
the mark on the brake camshaft (6) • Screw in the control arm mounting bolt and tighten
• Insert the brake wear sensor mounting bolt (5) into it to 22 Nm
the slack adjuster and fit the brake wear sensor (2) • Insert the cotter pin and secure using a new split
on the brake camshaft (6) pin
• Insert the shim (3) into the brake wear sensor (2)
• Attach a new circlip (4) in the brake camshaft (6)
• Check the axial play on the brake camshaft (6)
• The maximum permitted axial play is 0.5-1 mm
• Adjust the axial play using suitable shims (3)
• Tighten the brake wear sensor mounting bolt (5)
to 3 ± 0.3 Nm
2 - 38 G5
DRUM BRAKE
Basic slack adjuster setting
Turning back the adjusting screw
• Use a ring spanner to turn the adjusting screw (1)

on the slack adjuster in the direction indicated by
the arrow until the brake linings contact the brake
drum
• Turn back the adjusting screw on the slack
adjuster (in the opposite direction to the arrow) by
approx. 270°
Checking the adjustment
• Check the slack adjuster adjustment function by

operating the service brake system several times
The adjusting screw with attached ring spanner must
move gradually until the clearance of 0.7+ 0.3 mm
is reached
G5 2 - 39
DRUM BRAKE
BRAKE CAMSHAFT
Removing and installing the brake camshaft/brake camshaft bearings
Includes
Removing and installing the planetary hub drive, see 3-55
Removing and installing the wheel hub, see 4-69
Removing and installing/checking the slack adjuster with indicator discs, see 2-29
Removing and installing/checking the slack adjuster with brake wear sensor, see 2-35
(1) Rotary shaft seal (4) Brake camshaft needle bearing

(2) Brake camshaft needle bearing (5) Rotary shaft seal
(3) Bearing bracket (6) Brake camshaft
Service products
G5 2 - 41
DRUM BRAKE
Special tools
[7] Removing device 80.99604-0013
• Removing the brake camshaft bearing rotary shaft

seal
• Removing the brake camshaft bearing needle
bearing
[8] Pressing tool 80.99604-0125
• Installing the brake camshaft bearing rotary shaft

seal
• Removing the brake camshaft needle bearing in
conjunction with:
• Installer bush [9]
[9] Installer bush 80.99617-0147

seal
• Installing the brake camshaft needle bearing in
conjunction with:
• Pressing tool [8]
• Plug-on handle [10]
• Washer [11]
[10] Plug-on handle 80.99617-0187

seal
conjunction with:
[11] Washer 80.99617-0144

seal
conjunction with:
2 - 42 G5
DRUM BRAKE
Removing the brake camshaft/brake camshaft Removing the outer needle bearing with rotary
bearings shaft seal
Removing the brake camshaft
• Insert both half shells (3) of the Removing device

[7] into the outer needle bearing (4)
• Pull the brake camshaft (2) out of the bearing • Insert the pressing tool (1) of the Removing device
bracket (1) [7] into the half shells (3) with the stepped side
facing the bearing bracket (2)
Removing the inner needle bearing with rotary • Press out the needle bearing (4) with rotary shaft
shaft seal seal (5)
• Insert both half shells (3) of the Removing device

[7] into the inner needle bearing (2)
• Insert the pressing tool (5) of the Removing device
[7] into the half shells (3) with the stepped side
facing the bearing bracket (4)
• Press out the needle bearing (2) with rotary shaft
seal (1)
G5 2 - 43
DRUM BRAKE
Installing the brake camshaft/brake camshaft Pressing in the outer rotary shaft seal
bearings
Knocking in the inner needle bearing
• Mount the Installer bush [9] (3) with the stepped

side facing the Pressing tool [8] (4)
• Fit the rotary shaft seal (2) onto the installer sleeve
with the open side facing the bearing bracket (1)
• Assemble the installer sleeve consisting of • Insert the Pressing tool [8] (4) into the needle
Plug-on handle [10] with Washer [11] and Pressing bearing for guiding
tool [8] (1) • Press the rotary shaft seal (2) into the bearing
• Place the Installer bush [9] (3) onto the Pressing bracket (1) until the stop is reached
tool [8] (1) with the stepped side facing the needle
Pressing in the inner rotary shaft seal
bearing
• Place the needle bearing (2) onto the installer
sleeve
• Knock the needle bearing (2) into the bearing
bracket (4) until the stop is reached
the needle bearing (2) and in the empty space in
the bearing bracket (4)
Knocking in the outer needle bearing
• Mount the Installer bush [9] (3) with the stepped

side facing the Pressing tool [8] (1)
• Fit the rotary shaft seal (2) onto the installer sleeve
with the open side facing the bearing bracket (4)
• Insert the Pressing tool [8] (1) into the needle
bearing for guiding
• Press the rotary shaft seal (2) into the bearing
• Place the Installer bush [9] (3) onto the Pressing
tool [8] (4) with the stepped side facing the needle
bearing
• Place the needle bearing (2) onto the installer
sleeve
• Knock the needle bearing (2) into the bearing
the needle bearing (2)
2 - 44 G5
DRUM BRAKE
Installing the brake camshaft
• Insert the brake camshaft (2) into the bearing

bracket (1)
G5 2 - 45
DRUM BRAKE
BACKING PLATE
Removing and installing the backing plate
Includes
Removing and installing/checking the slack adjuster with indicator discs, see 2-29
Removing and installing/checking the slack adjuster with brake wear sensor, see 2-35
Removing and installing the brake camshaft/brake camshaft bearings, see 2-41
(1) Cover plate (4) Mounting bolts for bearing bracket

(2) Bearing bracket (5) Mounting bolts for backing plate
(3) Backing plate (6) Mounting bolt for cover plate
Technical data
Mounting bolts for backing plate (5) ....................... M16x1.5x50-10.9 ..................................... 280 ± 30 Nm
Mounting bolts for backing plate (5) ....................... M16x1.5x60-10.9 ..................................... 280 ± 30 Nm
Mounting bolts for backing plate (5) ....................... M16x1.5x140-10.9 ................................... 280 ± 30 Nm
Mounting bolts for bearing bracket (4).................... M16x1.5x70-10.9 ..................................... 300 ± 30 Nm
Mounting bolts for cover plate (6) .......................... M10x12-8.8 .......................................................45 Nm
G5 2 - 47
DRUM BRAKE
Service products
2 - 48 G5
DRUM BRAKE
Removing the backing plate Removing the clamping sleeve
Removing cover plates
• Pull the ABS sensor clamping sleeve (1) out of the

backing plate
• Unscrew the mounting bolts (1) from the cover
plates (2) and (3) Removing the bearing bracket
• Remove the cover plate (2) and, at the same time,
remove the grommet with ABS sensor cable from
the recess in the cover plate (2)
• Remove the cover plate (3)
Removing the ABS sensor
• Unscrew the mounting bolts (2) from the bearing

bracket (1)
• Pull the bearing bracket (1) out of the backing plate
Removing the backing plate
WARNING
Danger of ABS sensor malfunction
• Do not remove the ABS sensor by force
• Check the ABS sensor and connecting
line for damage and signs of melting,
renew as necessary
• Disconnect the ABS sensor electrical connection

• Pull the ABS sensor (1) out of the backing plate
Note
Note the different lengths of mounting bolt
and mark as necessary.
G5 2 - 49
DRUM BRAKE
• Mark the position of the backing plate (1) relative Mounting the backing plate
to the steering knuckle
• Unscrew the mounting bolts (2), (3) and (4) from
the backing plate (1)
• Remove the backing plate (1)
Note
Renew the backing plate mounting bolts.
• Position the backing plate (1) as marked

• Screw in the mounting bolts (2), (3) and (4) and
tighten them by hand
• Tighten the mounting bolts (2) to 280 ± 30 Nm
Installing the bearing bracket
Note
Renew the bearing bracket collar nuts.
• Insert the bearing bracket (1) into the backing plate

• Insert the mounting bolts (2) for the bearing
bracket (1) through the backing plate and bearing
bracket (1) and screw on the collar nuts
• Tighten the mounting bolts (2) for the bearing
bracket (1) to 300 ± 30 Nm
2 - 50 G5
DRUM BRAKE
Installing the clamping sleeve Mounting cover plates
• Lightly apply MAN 284 Li-H2 high-temperature

WARNING
grease on the ABS sensor contact surface in the
clamping sleeve
• Route the ABS cable so that there is no
• Insert the ABS sensor clamping sleeve (1) into the
risks of kinks or chafing
backing plate until the stop is reached
• Route the ABS sensor cable so that
Installing the ABS sensor there is no risk of strain
• Insert the grommet with the ABS sensor cable into

the recess in the cover plate (2)
• Mount the cover plates (2) and (3)
• Screw in the mounting bolts (1) and tighten them
to 45 Nm
WARNING
• Do not install the ABS sensor by force
Note
Do not fully insert the ABS sensor until
the wheel hub has been mounted, see
Removing and installing the wheel hub,
4-69.
• Insert the ABS sensor (1) into the clamping sleeve

in the backing plate
• Connect the electrical connection for the ABS
sensor (1)
G5 2 - 51
PLANETARY HUB DRIVE
PLANETARY HUB DRIVE
(1) Circlip (12) Planetary carrier fitted collar bolt

(2) Circlip (13) Shim
(3) Supporting ring (14) Bell hub cover seal
(4) Planetary carrier (15) Bell hub cover
(5) Sun gear (16) Retainer
(6) Planet gear (17) Grooved nuts
(7) Bearing needles (18) Thrust washer
(8) Planet gear shaft (19) Ring gear
(9) O-ring (20) Ring gear carrier
(10) Bell hub (21) Retaining ring
(11) Thrust washer (22) Wheel hub
G5 3 - 53
PLANETARY HUB DRIVE
PLANETARY HUB DRIVE
Removing and installing the planetary hub drive
Includes
For oil fill quantities, see Maintenance Manual
(1) Planetary carrier (10) Circlip

(2) Sun gear (11) Bell hub cover seal
(3) Supporting ring (12) Bell hub cover
(4) Circlip (13) Retainer
(5) O-ring (14) Grooved nuts
(6) Bell hub (15) Thrust washer
(7) Thrust washer (16) Ring gear with ring gear carrier
(8) Shim (17) Bell hub mounting bolts
(9) Planetary carrier fitted collar bolts (18) Wheel hub
Technical data
Bell hub mounting bolts (17).................................. M12x35x1.5-8.8 .................................................75 Nm
Bell hub cover mounting bolts (12)......................... M10x20 .............................................................95 Nm
Checking and filler plugs ....................................... M14x1.5-10.9.....................................................95 Nm
Permitted axial play on sun gear (2)......................................................................................0.30-0.40 mm
Thickness of shims (8) ..................................................................................................0.1/0.2/0.5/1.0 mm
G5 3 - 55
PLANETARY HUB DRIVE
Service products
Gear oil........................................................................................................................ MAN-Norm M 342
Special tools
[12] Puller screw 06.01734-4320
• Removing the bell hub
[13] Internal circlip pliers 08.04046-9000
• Removing and installing the thrust washer circlip
[14] Dial gauge 08.71000-3217
• Checking the sun gear axial play in conjunction

with:
• Dial gauge holder [15]
[15] Dial gauge holder 08.71082-0005
• Checking the sun gear axial play in conjunction

with:
• Dial gauge [14]
[16] Universal hand pump 80.99629-6005
• Filling the planetary hub drive with oil in

conjunction with:
• Measuring jug [17]
[17] Measuring jug 80.99629-0030
• Filling the planetary hub drive with oil in

conjunction with:
• Universal hand pump [16]
3 - 56 G5
PLANETARY HUB DRIVE
Removing the planetary hub drive Removing the thrust washer
Marking the position of the planetary hub drive

relative to the wheel hub
• Detach the circlip (3) using the Internal circlip pliers

[13] (4)
• Remove the shim (2) and the thrust washer (1)
• Mark the position of the planetary hub drive (2) from the bell hub
relative to the wheel hub (1)
Removing the supporting ring
Removing the bell hub cover
• Detach the circlip (2)

WARNING • Remove the supporting ring (1)
Danger of environmental pollution.
• Collect the emerging oil in a suitable Unscrewing the planetary hub drive mounting
container and dispose of in the correct bolts
manner
• Drain the oil from the planetary hub drive

• Mark the position of the bell hub cover (2) relative
to the planetary hub drive
• Unscrew the mounting bolts (3) and the oil filler
plugs
• Remove the planetary hub drive cover (2) with the
seal (1)
• Unscrew the planetary hub drive mounting bolts

(1)
G5 3 - 57
PLANETARY HUB DRIVE
Pressing off the planetary hub drive Installing the planetary hub drive
Installing the sun gear
• Screw the Puller screw [12] (3) into the planetary

hub drive (2) and press it off evenly
• Remove the planetary hub drive (2) with O-ring • Place the thrust washer (1) onto the stepped side
(1) of the sun gear
• With the stepped side facing the wheel hub, slide
Removing the sun gear the sun gear (2) onto the double-joint shaft until
the stop is reached
Mounting the planetary hub drive
• Pull the sun gear (2) and the thrust washer (1) off
the double-joint shaft
• Fit a new O-ring (1) on the planetary hub drive (2)

• Align the marking on the planetary hub drive (2)
with the marking on the wheel hub (1)
• Mount the planetary hub drive (2) with O-ring (1)
3 - 58 G5
PLANETARY HUB DRIVE
Screwing in the planetary hub drive mounting • Attach the circlip (3) in the planetary hub drive
bolts groove using the Internal circlip pliers [13] (4)
Checking the sun gear axial play
• Screw in new planetary hub drive mounting bolts

(1) and tighten them to 75 Nm
Installing the supporting ring Note

Shims are available in thickness sizes of
0.1/0.2/0.5/1.0 mm .
• Mount the Dial gauge [14] (5) on the Dial gauge

holder [15] (4)
• Position the Dial gauge holder [15] (4) on the
planetary hub drive (2)
• Place the Dial gauge [14] (5) against the thrust
washer (3) with a preload
• Press the thrust washer into the planetary hub
drive and zero the Dial gauge [14] (5)
• Press the double-joint shaft (1) towards the Dial
gauge [14] (5) and read the value shown on the
Dial gauge [14] (5)
• Set an axial play of 0.30-0.40 mm by inserting
• Fit the supporting ring (1) with the inside chamfer suitable shims
facing the double-joint shaft • Remove the gauge
• Attach the circlip (2) in the double-joint shaft
Mounting the bell hub cover
groove
Installing the thrust washer
Note
Renew the bell hub cover mounting bolts
• Insert the thrust washer (1) into the planetary hub (3).
drive
• Insert the shim (2) into the planetary hub drive
• Mount the bell hub cover (2) with a new seal (1)
G5 3 - 59
PLANETARY HUB DRIVE

to 95 Nm
Filling with gear oil
Note
Add the gear oil slowly so that it spreads
evenly around the lubricating area in
order to avoid obtaining a false oil level
reading.
• Turn the planetary hub drive until one of the

checking and filler holes (2) is 7° past the 3
o'clock position
• Use the Universal hand pump [16] to add Gear oil
through the filler hole (1) until Gear oil emerges
from the checking hole (2)
• Screw in the checking and filler hole plugs and
tighten them to 95 Nm
3 - 60 G5
PLANETARY HUB DRIVE
Disassembling and assembling the planetary hub drive
Includes
(1) Planetary carrier (10) Circlip

(2) Sun gear (11) Bell hub cover seal
(3) Supporting ring (12) Bell hub cover
(4) Circlip (13) Retainer
(5) O-ring (14) Inner grooved nut
(6) Bell hub (15) Thrust washer
(7) Thrust washer (16 Ring gear with ring gear carrier
(8) Shim (17) Bell hub mounting bolts
(9) Planetary carrier fitted collar bolts (18) Wheel hub with pulse wheel
Technical data
Planetary carrier fitted collar bolts (9)..................... M14x1.5-10.9........................................... 240 ± 20 Nm
Service products
MAN 283 Li-P2 multipurpose grease .................................................................................. 09.15001-0009
G5 3 - 61
PLANETARY HUB DRIVE
Note
When carrying out repairs, refer to the installation specifications and ensure that the correct
tolerance groups are used for the bearing needles in the planet gears.
The tolerance group for the bearing needles (0-2 µm) is marked in red on the bearing needle
packaging. These needle bearings are for planet gears with a yellow mark.
The tolerance group for the bearing needles (4-6 µm) is marked in white on the bearing needle
packaging. These needle bearings are for planet gears with a black mark.
Special tools
[18] Pressing tool 80.99604-0112
• Pressing in the planetary carrier
[19] Pressing tool 80.99617-0029
• Pressing out the planet gear shafts
[20] Clamping plate 80.99613-0003
• Clamping the planetary hub drive
3 - 62 G5
PLANETARY HUB DRIVE
Disassembling the planetary hub drive • Unscrew the fitted collar bolts (2)
Disassembling the ring gear Pressing off the planetary carrier
• Unscrew the retaining ring (1) from the groove in

the ring gear (3)
• Secure the planetary carrier to prevent it from
• Remove the ring gear carrier (2) from the ring gear
falling
(3)
• Use the Pressing tool [19] (2) to evenly press the
Marking the position of the planetary carrier planet gear shafts (1) out of the bell hub (3)
relative to the bell hub • Remove the bell hub (3) from the Clamping plate
[20]
Removing the planet gears
• Mark the position of the planetary carrier (2)

relative to the bell hub (1) using punch marks
Undoing the fitted collar bolts • Remove the outer thrust washer (1) from the
planet gear (2)
• Fit a thin-walled tube (3) with the same outside
diameter as the planet gear shafts
• Keep each planet gear (2) with needle bearings,
washer and thrust washers separate so that it can
be reused
• Mount the planetary hub drive (3) on the Clamping

plate [20] (1)
G5 3 - 63
PLANETARY HUB DRIVE
Removing the planet gear shafts Assembling the planetary hub drive
Assembling the ring gear
• Press the planet gear shaft (3) out of the planetary

carrier (2) using the Pressing tool [19] (1)
• Insert the ring gear carrier (2) into the ring gear
(3) and screw in the retaining ring (1) clockwise,
seating it as necessary
Pressing in the planet gear shaft
• Insert the planet gear shaft (2) into the planetary

carrier (3) with the oil bore facing outwards and
press it into the planetary carrier (3) using the
Pressing tool [19] (1)
3 - 64 G5
PLANETARY HUB DRIVE
Inserting the bearing needles • Fit the outer thrust washer (1) on the planet gear
shaft
Installing the planetary carrier
Note
If the bearing needles cannot be paired as
they were before when the bearing was
installed, they must be renewed.
A single planet carrier may incorporate
bearing needles from different tolerance
groups; however, a single planet
gear must only incorporate bearing
needles from the same tolerance group
(red/yellow and white/black).
• Apply a thin coat of MAN 283 Li-P2 multipurpose

grease on the inside of the planet gear
• Insert the lower row of bearing needles, fit the
washer (2) and insert the upper row of bearing
needles (1) into each planet gear
Installing the planet gears • Fit the bell hub (1) over the planetary carrier (2)
and onto the planet gear shafts, as marked
• Centre the planetary carrier relative to the bell hub
(1) using new fitted collar bolts
• Use the Pressing tool [18] to press the bell hub (1)
onto the planet gear shafts
Tightening the fitted collar bolts
WARNING
Danger of planet gear damage
• Install the thrust washers with the
lubricating groove facing the planet
gear
• Fit the inner thrust washer (3) on the planet gear • Mount the bell hub (3) on the Clamping plate [20]
shaft (1)
• Carefully slide the planet gear (2) onto the planet • Screw in the fitted collar bolts (2) and tighten them
gear shaft to 240 ± 20 Nm
• Check that the planet gears turn smoothly
G5 3 - 65
PLANETARY HUB DRIVE
• Remove the bell hub (3) from the Clamping plate

[20] (1)
3 - 66 G5
WHEEL HUB
WHEEL HUB
(1) Outer rotary shaft seal (8) Wheel bolt

(2) Inner rotary shaft seal (9) Outer grooved nut
(3) Race (10) Retainer
(4) Inner tapered roller bearing (11) Inner grooved nut
(5) Inner bearing outer race (12) Ring gear with ring gear carrier
(6) Pulse wheel (13) Outer tapered roller bearing
(7) Wheel hub (14) Outer bearing outer race
G5 4 - 67
WHEEL HUB
WHEEL HUB
Removing and installing the wheel hub
Includes

Technical data
Tightening torque for inner grooved nut (11) ...................................................................................550 Nm
Tightening torque for outer grooved nut (9) ....................................................................................550 Nm
Undoing angle for inner grooved nut (11) ............................................................................................. 60°
Installation temperature for inner tapered roller bearing (4) .............................................................. 130 °C
Installation temperature for race (3) ................................................................................................ 130 °C
Service products
G5 4 - 69
WHEEL HUB
Special tools
[21] Grooved nut spanner socket 80.99603-6001
• Removing and installing the wheel hub in

conjunction with:
[22] Adapter 80.99606-0519
• Removing and installing the wheel hub

• Removing the inner tapered roller bearing in
conjunction with:
• Removal sleeve [25]
• Removing device [26]
• Adapter [27]
• Thrust piece [23]
• Quick gripper [24]
[23] Thrust piece 80.99609-0026

conjunction with:
• Adapter [27]
• Adapter [22]
[24] Quick gripper 80.99628-0081

conjunction with:
• Adapter [27]
• Adapter [22]
[25] Removal sleeve 80.99601-0171

conjunction with:
• Adapter [27]
• Adapter [22]

conjunction with:
• Adapter [27]
• Adapter [22]
4 - 70 G5
WHEEL HUB
[27] Adapter 80.99634-0001

conjunction with:
• Adapter [22]
[28] Threaded spindle 80.99606-0240
• Fitting the wheel hub in conjunction with:

• Fitting cover [30]
• Fitting sleeve [31]
• T-handle [29]
• Adapter [22]
[29] T-handle 80.99606-0241

• Threaded spindle [28]
• Adapter [22]
[30] Fitting cover 80.99606-0239

• T-handle [29]
• Adapter [22]
[31] Fitting sleeve 80.99606-0243

• T-handle [29]
• Adapter [22]
G5 4 - 71
WHEEL HUB
Removing the wheel hub Removing the wheel hub
Removing the grooved nuts
• Pull off the wheel hub (2) with wheel bearing (3)
over the Adapter [22] (1)
• Release the outer grooved nut (3)
• Unscrew the outer grooved nut (3) using the Assembling the extractor tool
Grooved nut spanner socket [21] (4)
• Remove the retainer
• Unscrew the inner grooved nut (2) using the
Grooved nut spanner socket [21] (4)
Removing the ring gear carrier
• Mount the Quick gripper [24] (3) on the Removal

sleeve [25] (2)
• Screw the Adapter [27] (4) into the Removal sleeve
[25] (2)
• Screw the Removing device [26] into the Adapter
[27] (2)
• Pull the ring gear with ring gear carrier (1) off the
steering knuckle Removing the inner tapered roller bearing
Mounting the adapter
• Insert the Thrust piece [23] (3) into the Adapter

[22] (2)
• Mount the Adapter [22] (1) on the steering knuckle
4 - 72 G5
WHEEL HUB
• Mount the extractor tool (4) and clamp the Quick Installing the wheel hub
gripper [24] by fitting the clamping sleeve behind
the tapered roller bearing (1) Installing the race
• Remove the tapered roller bearing (1) by screwing
in the threaded spindle
• Remove the Adapter [22] (2)
Removing the race
CAUTION
Danger of injury due to hot
components
• Wear protective gloves
CAUTION • Heat the race (1) to 130 °C

Danger of injury due to hot • Slide the race (1) onto the axle tube until the stop
components is reached, making sure that the chamfered side
• Wear protective gloves is facing inwards
• Lightly apply Gear oil on the contact surface of the
• Remove the brake shoes, see Removing and race (1)
installing brake shoes, 2-17 • Mount the brake shoes, see Removing and
• Heat the race (2) at the height of the ABS sensor installing brake shoes, 2-17
hole
• Insert a drift through the ABS sensor hole (1) and Installing the inner tapered roller bearing
strike the race (2)
• Pull off the race (2)
CAUTION
Danger due to hot components
• Heat the tapered roller bearing (1) to 130 °C

• Mount the tapered roller bearing (1) on the steering
knuckle, making sure that the stop is reached, and
seat it as necessary
G5 4 - 73
WHEEL HUB
Assembling the fitting tool Fitting the wheel hub
• Screw the Fitting cover [30] (1) into the Fitting • Mount the fitting tool (2)
sleeve [31] (2) • Fit the wheel hub (1) by turning the T-handle (3)
• Screw the T-handle [29] (4) onto the Threaded clockwise until the stop is reached
spindle [28] (3) • Remove the fitting tool (2)
• Insert the Threaded spindle [28] (3) into the Fitting
cover [30] (1) Mounting the ring gear carrier
Mounting the wheel hub
• Fit the ring gear with ring gear carrier (1) onto the
steering knuckle
WARNING Adjusting the wheel bearings
Danger of wheel hub and steering
knuckle damage
• Do not place the wheel hub on the
steering knuckle for mounting
• Mount the Adapter [22] (1) on the steering knuckle

• Fit the wheel hub (2) over the Adapter [22]
• Insert the tapered roller bearing (3) into the wheel
hub (2)
• Screw on the inner grooved nut (2) and tighten by

hand
• Use the Grooved nut spanner socket [21] (4) to
tighten the inner grooved nut (2) to 550 Nm whilst
continuously turning the wheel hub
4 - 74 G5
WHEEL HUB
• Undo the inner grooved nut (2) by 60°

• Fit the retainer
• Screw on the outer grooved nut (3) and tighten by
hand
• Use the Grooved nut spanner socket [21] to screw
on the outer grooved nut (3) and tighten it to 550
Nm
• Secure the grooved nuts (2) and (3) by bending
over a tab on the retainer into a recess on the
inner grooved nut (2) and a recess on the outer
grooved nut (3)
G5 4 - 75
WHEEL HUB
Disassembling and assembling the wheel hub
Includes

Service products
MAN 283 Li-P2 high-temperature grease ............................................................................ 09.15001-0009
4 - 76 G5
WHEEL HUB
Special tools
[32] Impact extractor 80.99602-0016
• Extracting the rotary shaft seals

• Installing the wheel bolts in conjunction with:
• Wheel bolt adapter [43]
• Extractor hook [33]
[33] Extractor hook 80.99602-0127
• Extracting the rotary shaft seals in conjunction

with:
• Impact extractor [32]
[34] Assembly plate 80.99606-6107
• Installing the outer bearing outer race

• Installing the inner bearing outer race
• Installing the rotary shaft seals
• Fitting the pulse wheel in conjunction with:
• Washer [39]
• Installer sleeve [35]
• Centring pin [37]
[35] Installer sleeve 80.99604-0204
• Installing the outer bearing outer race in

conjunction with:
• Washer [39]
• Assembly plate [34]
• Installing the inner bearing outer race in

conjunction with:
• Washer [39]
[37] Centring pin 80.99606-0507

• Installing the rotary shaft seal in conjunction with:
• Washer [39]
G5 4 - 77
WHEEL HUB
[38] Plug-on handle 80.99617-0188
• Removing the inner bearing outer race

• Removing the outer bearing outer race
• Installing the rotary shaft seal
• Washer [39]
• Thrust washer [42]
• Reversible pressing tool [40]
[39] Washer 80.99617-0144

[40] Reversible pressing tool 80.99604-0203

• Washer [39]

• Removing the outer bearing outer race in
conjunction with:
• Thrust washer [42]
[42] Thrust washer 80.99617-0189

• Removing the bearing outer race in conjunction
with:
[43] Wheel bolt adapter 80.99602-0197
• Installing the wheel bolts in conjunction with:

4 - 78 G5
WHEEL HUB
Dismantling the wheel hub Removing the inner bearing outer race
Removing rotary shaft seals
Note
• Mount the Extractor hook [33] (2) on the Impact Expand the Removing device [41] (3),
extractor [32] (1) making sure that it is not wedged tight
• Position the Extractor hook [33] (2) below the outer in the wheel hub (4).
rotary shaft seal (3)
• Extract the outer rotary shaft seal (3) from the • Place the Thrust washer [42] (2) onto the Plug-on
wheel hub (5) using the Impact extractor [32] handle [38] (1)
• Position the Extractor hook [33] (2) below the inner • Place the Removing device [41] (3) onto the
rotary shaft seal (4) Plug-on handle [38] (1)
• Extract the inner rotary shaft seal (4) from the • Mount the Removing device [41] (3) with the
wheel hub (5) using the Impact extractor [32] (1) Thrust washer [42] (2) and the Plug-on handle
[38] (1) onto the inner bearing outer race (5)
• Clamp the Removing device [41] (3) until the stop
is reached by turning on the Plug-on handle [38]
• Use the hydraulic press to press the inner bearing
outer race (5) out of the wheel hub (4)
G5 4 - 79
WHEEL HUB
Removing the outer bearing outer race • Remove the pulse wheel (2) from the wheel hub
(1)
• Turn over the wheel hub (4)

• Mount the Removing device [41] (3) with the
Thrust washer [42] (2) and the Plug-on handle
[38] (1) onto the outer bearing outer race (5)
• Clamp the Removing device [41] (3) until the stop
is reached by turning on the Plug-on handle [38]
• Use the hydraulic press to press the outer bearing
outer race (5) out of the wheel hub (4)
Removing the pulse wheel
Note
Do not damage the wheel hub and
pulse wheel as this will cause ABS
malfunctions.
4 - 80 G5
WHEEL HUB
Assembling the wheel hub Installing the pulse wheel
Mounting the assembly plate
• Align the Assembly plate [34] (1) with plastic insert

relative to the wheel hub (2) and mount onto the
wheel hub (2)
Inserting the aligning punch
Note
Do not damage the wheel hub and
pulse wheel as this will cause ABS
malfunctions.
• Insert the pulse wheel (3) in the turned side of the

Reversible pressing tool [40] (2)
• Place the Reversible pressing tool [40] (2) over the
• Insert the wide side of the aligning punch (1)
Centring pin [37] (4) and onto the wheel hub (5)
through the wheel hub (2) and into the guide of
• Insert the Plug-on handle [38] (1) with the Washer
the Assembly plate [34]
[39] into the Reversible pressing tool [40] (2)
• Press the pulse wheel (3) onto the wheel hub (5)
until the stop is reached
G5 4 - 81
WHEEL HUB
Installing the inner bearing outer race Installing the inner rotary shaft seal
• Place the inner bearing outer race (3) onto the

Note
Installer sleeve [36] (4)
The inner and outer rotary shaft seals
• Insert the Installer sleeve [36] (4) over the Centring
differ by virtue of the number of sealing
pin [37] (2) and into the wheel hub (1)
lips.
First press in the rotary shaft seal with
[39] into the Installer sleeve [36] (4)
one sealing lip.
• Press the inner bearing outer race (3) into the
wheel hub (1) until the stop is reached
• Pack the open side of the rotary shaft seal (4) with
MAN 283 Li-P2 high-temperature grease
• Place the closed side of the rotary shaft seal (4)
onto the stepped side of the Reversible pressing
tool [40]
• Insert the Reversible pressing tool [40] (3) over the
Centring pin [37] (1) and into the wheel hub (5)
• Press the rotary shaft seal (4) into the wheel hub
(5) until the stop is reached
4 - 82 G5
WHEEL HUB
Installing the outer rotary shaft seal Removing the assembly plate
• Remove the assembly plate (2) from the wheel

hub (1)
Installing the outer bearing outer race
Note
The outer rotary shaft seal has two
sealing lips.
MAN 283 Li-P2 high-temperature grease
onto the stepped side of the Reversible pressing
tool [40] (3)
• Insert the Reversible pressing tool [40] (3) over the
Centring pin [37] (1) and into the wheel hub (5)
• Press the rotary shaft seal (4) into the wheel hub
(5) until the stop is reached
• Insert the wheel hub (5) into the plastic insert of

the Assembly plate [34] (6)
• Insert the aligning punch (1) through the wheel
hub (5) and into the guide of the Assembly plate
[34] (6)
• Place the outer bearing outer race (4) onto the
Installer sleeve [35] (3)
• Insert the Installer sleeve [35] (3) over the Centring
pin [37] (1) and into the wheel hub (5)
[39] into the Installer sleeve [35] (3)
G5 4 - 83
WHEEL HUB
• Press the outer bearing outer race (4) into the Removing the wheel bolts
wheel hub (5) until the stop is reached
Note
The wheel hub must be mounted when
this work is carried out, see Removing
and installing the wheel hub, 4-69
• Knock the wheel bolt (1) out of the wheel hub (2)
4 - 84 G5
WHEEL HUB
Installing the wheel bolts
Note
The wheel hub must be mounted when
this work is carried out, see Removing
and installing the wheel hub, 4-69
• Insert a new wheel bolt (1) with the truncated end

facing the wheel hub
• Screw the Wheel bolt adapter [43] (2) onto the
wheel bolt
• Knock in the wheel bolt (1) using the Wheel bolt
adapter [43] (2) and the Impact extractor [32] (3)
G5 4 - 85
WHEEL HUB
ABS COMPONENTS
Removing and installing the ABS components
Includes
(1) ABS sensor (3) Pulse wheel

(2) Clamping sleeve
Service products
G5 4 - 87
WHEEL HUB
Removing the ABS components Installing the ABS components
Removing the ABS sensor Installing the clamping sleeve
• Insert the ABS sensor clamping sleeve (1) into the

WARNING
backing plate until the stop is reached
• Lightly apply MAN 284 Li-H2 high-temperature
• Do not remove the ABS sensor by force
grease on the ABS sensor contact surface in the
Note clamping sleeve
Check the ABS sensor and connecting
line for damage and signs of melting, Installing the ABS sensor
renew as necessary
• Disconnect the ABS sensor electrical connection

(1)
• Pull the ABS sensor (1) out of the backing plate
Removing the clamping sleeve
WARNING
• Do not install the ABS sensor by force
Note
Check the ABS sensor and connecting
line for damage and signs of melting,
• Pull the ABS sensor clamping sleeve (1) out of the renew as necessary
backing plate
• Insert the ABS sensor (1) into the clamping sleeve
• Connect the electrical connection for the ABS
sensor (1)
• Turn the wheel hub two or three times to set the
clearance for the ABS sensor (1)
4 - 88 G5
STEERING KNUCKLE
STEERING KNUCKLE
(1) Steering knuckle arm (9) Steering knuckle bushing

(2) Steering knuckle bushing (10) External hexagonal round screw
(3) Rotary shaft seal (11) Circlip
(4) Sliding block (12) Cover
(5) Sliding block (13) Screw plug with sealing ring
(6) Lower kingpin (14) Upper kingpin
(7) Screw plug with sealing ring (15) Rotary shaft seal
(8) Fitted washer (16) Steering knuckle
G5 5 - 89
STEERING KNUCKLE
STEERING KNUCKLE
Removing and installing the steering knuckle
Includes
For oil fill quantities, see Maintenance Manual
Removing and installing the backing plate, see 2-47
Removing and installing the track rod/steering arm, see 9-181
(1) Sliding block (7) Sealing ring

(2) Lower kingpin (8) Cover
(3) Sealing ring (9) Upper kingpin
(4) Screw plug (10) Fitted washer
(5) External hexagonal round screws (11) Steering knuckle arm
(6) Screw plug (12) External hexagonal round screw
Technical data
External hexagonal round screws (5) and (12) ....... M16x1.5x55-10.9 ..................................... 310 ± 30 Nm
Lock nut, steering lock bolt.................................... M14x1.5 ..........................................................125 Nm
Steering knuckle axial play............................................................................................................ 0.0 mm
Steering knuckle preload............................................................................................................... 0.1 mm
G5 5 - 91
STEERING KNUCKLE
Thickness of sliding block for kingpin (2) ...................................................................... 9.0 mm or 10.0 mm

Thickness of sliding block for steering knuckle arm (1)...............................................................8.8-9.7 mm
Preheating temperature for lower axle beam end............................................................................. 130 °C
Test sliding block for kingpin (2)..................................................................................................... 9.0 mm
Test sliding block for steering knuckle arm (11)............................................................................... 8.8 mm
Service products
DS1KG high-temperature paste ......................................................................................... 09.16012-0115
Special tools
• Removing the steering knuckle cover
• Extracting the lower kingpin
[46] Extractor device 80.99602-0017
• Extracting the steering knuckle bushing
• Draining and filling the kingpin oil
[48] Plug-on handle 80.99617-0188
• Installing the steering knuckle bushing in

conjunction with:
• Washer [49]
[49] Washer 80.99617-0144

conjunction with:
5 - 92 G5
STEERING KNUCKLE

conjunction with:
• Washer [49]
[51] Axle beam end heater 80.99621-0004
• Preheating the lower axle beam end
[52] Dial gauge 08.71000-3217
• Checking the steering knuckle axial play in

conjunction with:
• Checking the steering knuckle axial play in

conjunction with:
• Dial gauge [52]
G5 5 - 93
STEERING KNUCKLE
Removing the steering knuckle Removing the cover
Removing the steering knuckle arm
WARNING
Danger of environmental pollution
WARNING • Collect the emerging oil and dispose of
Danger of environmental pollution it in the correct manner
• Collect the emerging oil and dispose of
it in the correct manner • Unscrew the screw plug (3) and remove the
sealing ring (4)
• Unscrew the external hexagonal round screws (3) • Extract the oil in the kingpin using the Universal
• Pull off the steering knuckle arm (2) hand pump [47]
• Remove the sliding block (1) from the steering • Unscrew the external hexagonal round screws (1)
knuckle arm (2) • Insert the rounded side of the pressure pin (6) of
the Removing device [44] (2) into the kingpin oil
filler hole
• Screw the Removing device [44] (2) into the
kingpin
• Press off the cover (5) by screwing in the pulling
screw of the Removing device [44] (2)
5 - 94 G5
STEERING KNUCKLE
Removing the fitted washer Extracting the steering knuckle bushing
• Use a magnet (1) to remove the fitted washer (2)

from the steering knuckle bore
Removing the lower kingpin
• Insert the clamping sleeve (2) of the Extractor

device [46] into the steering knuckle bushing (6)
until the stop is reached, making sure that the
clamping sleeve (2) engages in the relief-turned
side (5) of the steering knuckle bushing (4)
• Insert the pressure pin (3) of the Extractor device
[46] into the clamping sleeve (2)
• Mount the cover (4) of the Extractor device [46] on
the clamping sleeve (2)
• Extract the steering knuckle bushing (6) from the
axle housing (1) by screwing in the pulling screw
• Remove the steering knuckle bushing (6) from the
Extractor device [46]
• Detach the circlip (3) from the kingpin (1)

• Remove the sliding block (2) from the kingpin (1)
• Mount the Removing device [45] (4) on the kingpin
(1)
• Use the Removing device [45] (4) to extract the
kingpin (1)
• Unscrew the oil filler plug with seal
G5 5 - 95
STEERING KNUCKLE
Removing the steering knuckle Mounting the steering knuckle
Installing the steering lock bolt
WARNING
Component damage due to incorrect • Screw the steering lock bolt (1) into the steering
handling of the steering knuckle knuckle (3) as marked
• Do not place the steering knuckle on • Tighten the lock nut for the steering lock bolt (1) to
the axle nut thread, screw grooved nut 125 Nm
onto steering knuckle as necessary • Insert the plug (2)
• Check the steering lock and adjust if necessary
• Remove the steering knuckle (2) from the axle
housing (1) Mounting the steering knuckle
Removing the steering lock bolt
• Secure the component to prevent it from dropping

down
• Mark the installation position of the steering lock • Fit the steering knuckle (2) over the double-joint
bolt (1) relative to the steering knuckle (3) shaft and axle housing (1)
• Undo the lock nut for the steering lock bolt (1) • Prevent the steering knuckle (2) from falling down
• Unscrew the steering lock bolt (1)
• Remove the plug (2)
5 - 96 G5
STEERING KNUCKLE
Installing the steering knuckle bushing Inserting the fitted washer
• Place the Washer [49] on the Plug-on handle [48] • Insert the fitted washer (1) into the axle housing
(2)
• Place the turned side of the Reversible pressing
tool [50] (3) on the Plug-on handle [48] (2)
• Place the steering knuckle bushing (4) on the
axle housing (1) with the chamfer facing the axle
housing (1)
• Insert the installer sleeve into the steering knuckle
bushing (4)
• Press the steering knuckle bushing (4) into the
axle housing (1) until the stop is reached
G5 5 - 97
STEERING KNUCKLE
Installing the cover Heating the lower axle beam end
Note CAUTION
Renew the external hexagonal round Danger due to hot components
screws (1). • Wear protective gloves
• Do not touch the heating surface of the
• Apply a light coating of DS1KG high-temperature axle beam end heater (2)
paste on the guide of the cover (2), making sure • Hold the axle beam end heater by the
that the contact surface of the cover (2) remains handle
free of grease
• Insert the Axle beam end heater [51] (2) into the
• Insert the cover (2) through the steering knuckle
lower axle beam end (1)
(3) and into the axle housing
• Heat the lower axle beam end (1) to 130 °C
• Screw in the external hexagonal round screws (1)
and tighten them to 310 ± 30 Nm
5 - 98 G5
STEERING KNUCKLE
Installing the lower kingpin Installing the steering knuckle arm
• Align the kingpin (1) with the axle beam end using
Note
the oil filler hole thread
Renew the external hexagonal round
• Insert the kingpin (1) into the axle beam end until
screws (3).
the stop is reached, using a soft hammer to seat it
if necessary
• Insert a test sliding block (2) of thickness 9.0 mm • Insert the test sliding block (1) 8.8 mm into the
into the kingpin (1) with the stepped side facing steering knuckle arm (2) with the chamfered side
downwards facing upwards
• Attach the circlip (3) in the groove of the kingpin • Apply a light coating of DS1KG high-temperature
(1) paste on the guide of the steering knuckle arm,
making sure that the contact surface of the
steering knuckle arm (2) remains free of grease
• Screw in the external hexagonal round screw (3)
and tighten it to 310 ± 30 Nm
G5 5 - 99
STEERING KNUCKLE
Checking and setting the axial play Filling with oil
Note • Use the Universal hand pump [47] to fill with Gear
To avoid false axial play readings, avoid oil through the oil filler hole in the kingpin, see
pushing the steering knuckle up and Maintenance Manual for fill quantities
down on the axle journal. • Repeat the same procedure for the other kingpins
• Screw in the screw plugs (1) and (3) with new seals
(2) and (4) and then tighten them
• Place the Dial gauge holder [53] (1) on the axle
housing
• Mount the Dial gauge [52] (2) on the Dial gauge
holder [53] (1)
• Place the Dial gauge [52] (2) against the cover of
the steering knuckle (3) with a preload
• Push the steering knuckle (3) downwards and zero
the Dial gauge [52] (2)
• Push the steering knuckle (3) upwards and read
off the axial play
• Replace both test sliding blocks with suitable
sliding blocks so that the steering knuckle (3) has
no play or a preload of 0.1 mm
5 - 100 G5
STEERING KNUCKLE
STEERING KNUCKLE
Dismantling and assembling the steering knuckle bearings
Includes
Removing and installing the track rod/steering arm, see 9-181
Removing and installing the steering knuckle, see 5-91
(1) External hexagonal round screws (11) Screw plug

(2) Steering knuckle arm (12) Upper kingpin
(3) Steering knuckle bushing (13) Fitted washer
(4) Rotary shaft seal (14) Steering knuckle
(5) Rotary shaft seal (15) Screw plug
(6) Steering knuckle bushing (16) Sealing ring
(7) Sealing ring (17) Lower kingpin
(8) Circlip (18) Sliding block
(9) External hexagonal round screws (19) Circlip
(10) Cover (20) Sliding block
Technical data
Pre-heating temperature for cover (10) ........................................................................................... 130 °C
G5 5 - 101
STEERING KNUCKLE
Service products
MAN 283 LI-P 2 high-temperature grease ........................................................................... 09.15001-0009
Special tools
[54] Extractor device 80.99602-0017
• Extracting the steering knuckle bushing
[55] Plug-on handle 80.99617-0188

conjunction with:
• Washer [56]
[56] Washer 80.99617-0144

conjunction with:

conjunction with:
• Washer [56]
• Extracting the rotary shaft seal in conjunction with:

[59] Extractor hook 80.99602-0127

[60] Axle beam end heater 80.99621-0004
• Pre-heating the cover
5 - 102 G5
STEERING KNUCKLE
Dismantling the steering knuckle bearings Extracting the steering knuckle bushing
Extracting the steering knuckle arm rotary shaft

seal
• Clamp the steering knuckle arm (5) in a vice with

protective jaws
• Insert the clamping sleeve (3) of the Extractor
• Extract the rotary shaft seal (3) from the steering device [54] into the steering knuckle bushing (4)
knuckle arm (4) using the Impact extractor [58] (1) until the stop is reached, making sure that the
and the Extractor hook [59] (2) clamping sleeve (3) engages in the relief-turned
side (6) of the steering knuckle bushing (4)
• Insert the pressure pin (2) of the Extractor device
[54] into the clamping sleeve (3)
• Mount the cover (1) of the Extractor device [54] on
the clamping sleeve (3)
• Extract the steering knuckle bushing (4) from the
steering knuckle arm (5) by screwing in the pulling
screw of the Extractor device [46]
• Remove the steering knuckle bushing (4) from the
Extractor device [46]
G5 5 - 103
STEERING KNUCKLE
Pressing out the kingpin Assembling the steering knuckle bearings
Installing the kingpin
• Detach the circlip (1) from the cover (2)

• Press the kingpin (3) out of the cover (2)
Extracting the cover rotary shaft seal
CAUTION
components
• Do not touch the heating surface of the
axle beam end heater (2).
• Hold the axle beam end heater by the
handle.
• Attach the circlip (4) in the cover (3)

• Insert the Axle beam end heater [60] (2) into the
cover (3)
• Heat the cover (3) to 130 °C
• Insert the kingpin (1) as far as the stop on the
circlip (4) with the tapped hole facing the cover (3)
and seat it as necessary
• Extract the rotary shaft seal (3) from the cover

(4) using the Impact extractor [58] (1) and the
Extractor hook [59] (2)
5 - 104 G5
STEERING KNUCKLE
Installing the cover rotary shaft seal • Place the steering knuckle busing (3) on the
Reversible pressing tool [50] (2) with the chamfer
facing the steering knuckle arm (4)
• Press the steering knuckle bushing (3) into the
steering knuckle arm (4) until the stop is reached
Installing the steering knuckle arm rotary shaft

seal
• Turn around the Reversible pressing tool [50] (2)

on the Plug-on handle [48] (1)
MAN 283 LI-P 2 high-temperature grease
• Place the rotary shaft seal (3) on the Reversible
pressing tool [50] (2) with the open side facing the
steering knuckle arm (4)
• Press the rotary shaft seal (3) into the steering
• Place the Washer [49] on the Plug-on handle [48]
knuckle arm (4) until the stop is reached
(1)
• Place the narrow side of the Reversible pressing
tool [50] (2) on the Plug-on handle [48] (1)
MAN 283 LI-P 2 high-temperature grease
on the Reversible pressing tool [50] (2)
• Press the rotary shaft seal (3) into the cover (4)
Installing the steering knuckle bushing

G5 5 - 105
DOUBLE-JOINT SHAFT
DOUBLE-JOINT SHAFT
(1) Axle housing (7) Race

(2) Needle bearing (8) Inner rotary shaft seal
(3) Inner rotary shaft seal (9) Outer rotary shaft seal
(4) Outer rotary shaft seal (10) Needle bearing
(5) Race (11) Thrust piece
(6) Double-joint shaft
G5 6 - 107
DOUBLE-JOINT SHAFT
DOUBLE-JOINT SHAFT
Removing and installing the double-joint shaft
Includes
(1) Axle housing (7) Race

(2) Needle bearing (8) Inner rotary shaft seal
(3) Inner rotary shaft seal (9) Outer rotary shaft seal
(4) Outer rotary shaft seal (10) Needle bearing
(5) Race (11) Thrust piece
(6) Double-joint shaft
Technical data
Installation temperature for needle bearing races (5) and (7)............................................................ 130 °C
Pressure switch for transverse differential lock .................................................................................35 Nm
Service products
MAN 283 LI-P2 high-temperature grease ............................................................................ 09.15001-0009
G5 6 - 109
DOUBLE-JOINT SHAFT
Special tools
[61] Heat accumulator 80.99606-0034
• Fitting the double-joint shaft bearing race
[62] Extractor anchor 80.99602-0032
• Extracting the needle bearing in conjunction with:

• Extracting the needle bearing in conjunction with:

• Extractor anchor [62]
[64] Plug-on handle 80.99617-0188
• Removing and installing the needle bearing and

rotary shaft seals in conjunction with:
• Drift punch [66]
• Washer [65]
[65] Washer 80.99617-0144
• Removing and installing the needle bearing and

rotary shaft seals in conjunction with:
• Drift punch [66]
[66] Drift punch 80.99617-0099
• Removing the needle bearing and rotary shaft

seals in conjunction with:
• Washer [65]
• Installing the needle bearing and rotary shaft

seals in conjunction with:
• Washer [65]
6 - 110 G5
DOUBLE-JOINT SHAFT
[68] Pressure spindle 80.99613-0027
• Locking the differential lock
[69] Octagon socket 80.99603-0261
• Removing and installing the differential lock

pressure switch
G5 6 - 111
DOUBLE-JOINT SHAFT
Removing the double-joint shaft Removing the needle bearing and rotary shaft
seals from the axle housing
Extracting the double-joint shaft
Note
The transverse differential lock only has
to be locked for removing and installing
the double-joint shaft on the lock side.
• Unscrew the pressure switch for the transverse

differential lock using the Octagon socket [69]
• Lock the transverse differential lock by screwing
the Pressure spindle [68] (1) into the selector
cylinder cover, turning the double-joint shaft if
necessary, until the sliding sleeve engages
• Extract the double-joint shaft (1) from the axle
housing (2)
• Assemble the Impact extractor [63] (3) and the
Extractor anchor [62] (2)
• Insert the extractor tool into the axle housing (1)
and clamp the Extractor anchor [62] (2) behind the
needle bearing (6)
• Extract the needle bearing (6) with rotary shaft
seals (4) and (5)
Removing the needle bearing and rotary shaft

seals from the steering knuckle
• Assemble the removing tool consisting of the

Plug-on handle [64] (6) with the Washer [65] and
the Drift punch [66] (5)
• Insert the removing tool through the steering
knuckle (4)
6 - 112 G5
DOUBLE-JOINT SHAFT
• Use the removing tool to press out the needle Installing the double-joint shaft
bearing (3) and rotary shaft seals (1) and (2)
Preparing to install the bearing race
Removing the race
CAUTION
CAUTION Danger of injury due to hot
Danger of injury due to material components
splintering • Wear protective gloves
• Wear protective glasses, protective
gloves and protective clothing • Mount the handle (3) on the Heat accumulator [61]
(1)
Note
• Insert the bearing race (2) into the Heat
The removal procedure is the same for
accumulator [61] (1) chamfered side first
both sides of the double-joint shaft.
• Heat the Heat accumulator [61] (1) with bearing
race (2) to 130 °C
• Remove the pressure piece (2)
• Grind off half of the material thickness of the race
(1)
• Prise open the race (1) using a chisel and pull it
off the double-joint shaft
G5 6 - 113
DOUBLE-JOINT SHAFT
Mounting the bearing race Installing the axle housing needle bearing

Plug-on handle [64] (4) with the Washer [65] (3)
and the Reversible pressing tool [67] (2)
• Place the needle bearing (1) on the stepped side
of the Reversible pressing tool [67] (3)
• Knock the needle bearing (1) into the axle housing
Installing the axle housing inner rotary shaft seal
CAUTION
components
Note
The installation procedure is the same for
both sides of the double-joint shaft.
• Clamp the holding fixture (1) for the Heat

accumulator [61] (2) Note
• Insert the Heat accumulator [61] (2) with bearing The inner and outer rotary shaft seals
race on handle (4) into the holding fixture (1) differ by virtue of the number of sealing
• Push the double-joint shaft (3) through the bearing lips.
race until the stop is reached First press in the rotary shaft seal with
one sealing lip.

MAN 283 LI-P2 high-temperature grease
onto the turned side of the Reversible pressing
tool [67] (2)
• Knock the rotary shaft seal (1) into the axle
housing until the stop is reached
6 - 114 G5
DOUBLE-JOINT SHAFT
Installing the axle housing outer rotary shaft seal Installing the steering knuckle inner rotary shaft
seal
Note
The rotary shaft seal has two sealing lips. Note
The inner and outer rotary shaft seals
differ by virtue of the number of sealing
lips.
First install the rotary shaft seal with just
one sealing lip.
• Knock the rotary shaft seal (1) into the axle
on the Plug-on handle [64]
housing until the stop is reached
Installing the steering knuckle needle bearing MAN 283 LI-P2 high-temperature grease
onto the turned side of the Reversible pressing
tool [67] (1)
• Knock the rotary shaft seal (4) into the steering
knuckle until the stop is reached
Installing the steering knuckle outer rotary shaft

seal

Plug-on handle [64] (1) with the Washer [65] (2)
and the Reversible pressing tool [67] (3)
• Place the needle bearing (4) on the stepped side
of the Reversible pressing tool [67] (3)
• Knock the needle bearing (4) into the steering
knuckle (5) until the stop is reached
• Knock the rotary shaft seal (2) into the steering
knuckle until the stop is reached
G5 6 - 115
DOUBLE-JOINT SHAFT
Installing the double-joint shaft
Note
The double-joint shaft on the lock side
has two splines on the longer side.
• Insert the double-joint shaft (1) into the axle

housing (2)
• Unscrew the Pressure spindle [68] (1)
• Use the Octagon socket [69] to screw in the
pressure switch and new seal
• Tighten the pressure switch to 35 Nm
Installing the thrust piece
• Insert the thrust piece (2) into the double-joint shaft

(1)
6 - 116 G5
AXLE DRIVE
AXLE DRIVE
(1) Oil baffle (17) Tapered roller bearing

(2) Inner bearing outer race (18) Threaded ring
(3) Inner tapered roller bearing (19) Bearing shell
(4) Drive pinion (20) Tab washer
(5) Axle drive housing (21) Tab washer mounting bolt
(6) Axle drive housing mounting bolt (22) Bearing shell mounting bolts
(7) Threaded ring (23) Axle drive mounting bolts
(8) Oil baffle (24) Drive pinion housing seal
(9) Bearing shell (25) Drive pinion housing
(10) Tapered roller bearing (26) Fitted washer
(11) Bearing shell mounting bolt (27) Outer bearing outer race
(12) Oil baffle (28) Bi-hexagonal nut
(13) Differential (29) Input flange
(14) Thrust washer (30) Rotary shaft seal
(15) Crown wheel (31) Outer tapered roller bearing
(16) Crown wheel mounting bolts (32) Drive pinion housing mounting bolt
G5 7 - 117
AXLE DRIVE
DRIVE SHAFT ROTARY SHAFT SEAL
Removing and installing the drive shaft rotary shaft seal
Includes
Draining and topping up the front axle oil, see Maintenance Manual
Removing and fitting the propshaft
(1) Bi-hexagonal nut (3) Rotary shaft seal

(2) Input flange (4) Drive pinion housing
Technical data
Bi-hexagonal nut (1) ............................................. M45x1.5 .................................................. 950 ± 50 Nm
G5 7 - 119
AXLE DRIVE
Special tools
[70] Socket 80.99603-0175
• Screwing on and unscrewing the bi-hexagonal nut

in conjunction with:
[71] Torque multiplier i = 1:8 83.09195-6001

• Socket [70]
• Adapter flange [72]
[72] Adapter flange 80.99610-0009

• Torque multiplier i = 1:8 [71]
• Socket [70]

[74] Extractor hook 80.99602-0179

[75] Plug-on handle 80.99617-0188

• Washer [76]
[76] Washer 80.99617-0144

7 - 120 G5
AXLE DRIVE

• Washer [76]
[78] Three-armed extractor 08.99605-9014
• Removing the input flange
G5 7 - 121
AXLE DRIVE
Removing the rotary shaft seal Removing the input flange
Releasing the bi-hexagonal nut
• Pull off the input flange using Three-armed

extractor [78] (1)
• Release the bi-hexagonal nut (1) (groove must be
free) Removing the rotary shaft seal
Assembling the special tool
• Use the Impact extractor [73] (1) and the Extractor

hook [74] (2) to extract the rotary shaft seal (3)
• Place the Socket [70] (3) on the bi-hexagonal nut
• Mount the Adapter flange [72] (2) on the Torque
multiplier i = 1:8 [71] (1)
Unscrewing the bi-hexagonal nut
• Mount the Torque multiplier i = 1:8 [71] (1) with

Adapter flange [72] (2) on the input flange (3) and
unscrew the bi-hexagonal nut (hidden by special
tool)
7 - 122 G5
AXLE DRIVE
Installing the rotary shaft seal Screwing on the bi-hexagonal nut
Pressing in the rotary shaft seal
• Mount the Torque multiplier i = 1:8 [71] (1) with the

Adapter flange [72] (2) on the input flange (3)
• Insert the Plug-on handle [75] (1) with the Washer • Tighten the bi-hexagonal nut (hidden by the
[76] into the Installer sleeve [77] (2) special tool) to 950 ± 50 Nm
• Place the closed side of the rotary shaft seal (3) • Remove the Torque multiplier i = 1:8 [71] (1) with
onto the thicker side of the Installer sleeve [77] (2) the Adapter flange [72] (2) from the input flange
• Press the rotary shaft seal (3) into the axle drive (3)
Locking the bi-hexagonal nut
Mounting the input flange
• Lock the bi-hexagonal nut (1) by indenting the

Note collar against the release direction in the groove
Renew the input flange (2) after
exchanging the rotary shaft seal.
• Place the new input flange (2) onto the drive

pinion, ensuring that the stop is reached
• Screw on a new bi-hexagonal nut (1) and tighten
it by hand
G5 7 - 123
AXLE DRIVE
AXLE DRIVE
Removing and installing the axle drive
Includes
Removing and installing the double-joint shaft, see 6-109
(1) Input flange (4) Axle drive

(2) Drive pinion housing (5) Axle housing
(3) Axle drive mounting bolt (6) Selector cylinder cover
Technical data
Axle drive mounting bolts (3) ................................. M12x1.5x35-12.9 ..................................... 135 ± 10 Nm
Axle drive mounting bolts ...................................... M12x1.5x40-12.9 ..................................... 135 ± 10 Nm
Axle drive mounting bolts ...................................... M12x1.5x105-12.9 ................................... 135 ± 10 Nm
Transverse differential lock, selector cylinder cover
mounting bolt (6) .................................................. M8x35-8.8 .........................................................22 Nm
G5 7 - 125
AXLE DRIVE
Pressure switch for transverse differential lock .................................................................................35 Nm

Axle filter mounting bolt......................................... M8x16-8.8 .........................................................22 Nm
Service products
Omnifit FD 3041 face sealing agent .................................................................................... 04.10160-9249
Special tools
[79] Lifting device 80.99606-0016
• Removing and installing the axle drive in

conjunction with:
• Assembly crown [80]
[80] Assembly crown 80.99606-0308
• Removing and installing the axle drive in

conjunction with:
• Lifting device [79]
• Locking the differential lock
[82] Octagon socket 80.99603-0261
• Removing and installing the differential lock

pressure switch
7 - 126 G5
AXLE DRIVE
Removing the axle drive Marking the mounting bolts
Removing the selector cylinder cover
Note
• Disconnect the electrical connections In the case of all other variants apart from
• Detach the compressed air connection for the the axle drive with 26 : 24 gear set, only
selector cylinder cover (2) the mounting bolts (1) have to be marked
• Remove the pressure switch (3) using the Octagon as the remaining mounting bolts are all of
socket [82] (4) and then remove the sealing ring the same length.
• Remove the selector cylinder cover (2) with gasket
(1) • Mark the mounting bolts (1) according to their
position relative to the axle drive housing (2)
Marking the mounting bolts, axle drive with 26 :
24 gear set Mounting the selector cylinder cover
• Mount the selector cylinder cover with gasket

Note • Tighten the selector cylinder cover mounting bolts
This procedure only applies to the axle to 22 Nm
drive with gear set i = 26 : 24, see model • Lock the transverse differential lock by screwing
plate. the Pressure spindle [81] (1) into the selector
cylinder cover, turning the double-joint shaft if
• Mark six mounting bolts (3) according to their necessary, until the sliding sleeve engages
position relative to the axle drive housing
• Mark two mounting bolts (2) according to their
• Mark eight mounting bolts (1) according to their
G5 7 - 127
AXLE DRIVE
Extracting the double-joint shafts Removing the axle drive with 26 : 24 gear set
• Extract both double-joint shafts (1) from the axle

Note
housing (2)
This procedure only applies to the axle
Mounting the lifting device drive with gear set i = 26 : 24, see model
plate.
The mounting bolts (1) and (2) are not
mounting bolts for the axle drive.
• Unscrew the axle drive mounting bolts

• Use hydraulic lifting device to extract the axle drive
from the axle housing
• Clean the sealing surfaces
Removing the axle drive
• Mount the Lifting device [79] (1) on the Assembly

crown [80] (3)
• Use hydraulic lifting gear to align the Lifting device
[79] (1) and Assembly crown [80] (3) with the input
flange (2) and mount them on the input flange (2)
• Align the support for the Lifting device [79] (1) with
the drive pinion housing
• Unscrew the relevant drive pinion housing
mounting bolt
• Mount the support for the Lifting device [79] (1)
• Unscrew the mounting bolts (1) from the axle
using the drive pinion housing mounting bolt
housing (2)
Tighten the mounting bolt so that the support cannot
• Use hydraulic lifting device to extract the axle drive
turn when mounted on the drive pinion housing.
from the axle housing (2)
• Clean the sealing surfaces
7 - 128 G5
AXLE DRIVE
Removing the axle filter Installing the axle drive
Installing the axle filter
• Unscrew the mounting bolts (1)

• Remove the axle filter (2)
• Fit the axle filter (2)
• Screw in new mounting bolts (1) and tighten to 22
Nm
Installing the axle drive with 26 : 24 gear set
Note
This procedure only applies to the axle
drive with gear set i = 26 : 24, see model
plate.
• Apply a light coating of Omnifit FD 3041 face

sealing agent on the axle drive sealing surfaces
• Insert the axle drive into the axle housing using
hydraulic lifting gear
• Mark the mounting bolts (1), (2) and (3) to indicate
their position
G5 7 - 129
AXLE DRIVE
Installing the axle drive Removing the selector cylinder cover
• Apply a light coating of Omnifit FD 3041 face • Unscrew the Pressure spindle [81] (1) from the
sealing agent on the axle drive sealing surfaces selector cylinder cover
• Insert the axle drive into the axle housing using • Remove the selector cylinder cover with gasket
hydraulic lifting gear
• Tighten the new mounting bolts (1) to 135 ± 10 Nm Screwing in the mounting bolts
Installing the double-joint shafts
• Screw the mounting bolts (1) into the free

mounting holes in the axle drive (2) as marked
Note
The double-joint shaft on the lock side
has two splines on the longer side.
• Insert both double-joint shafts (1) into the axle

housing (2)
7 - 130 G5
AXLE DRIVE
Mounting the selector cylinder cover
Note
Note the installation position of the gasket
for the selector cylinder cover (2).
The gasket (1) for the selector cylinder
cover (2) must always be installed with
the black side facing the cover.
• Mount the selector cylinder cover (2) with a new

gasket (1)
• Tighten the mounting bolts to 22 Nm
• Screw in the pressure switch (3) with a new sealing
ring (1) and tighten it by hand
• Use the Octagon socket [82] (4) to tighten the
pressure switch to 35 Nm
• Connect the electrical connections
• Attach the compressed air connection for the
selector cylinder cover (2)
G5 7 - 131
AXLE DRIVE
DIFFERENTIAL
Removing and installing/adjusting the differential
Includes
Removing and installing the axle drive, see 7-125
(1) Threaded ring (10) Tapered roller bearing

(2) Oil baffle (11) Bearing shell
(3) Bearing shell (12) Tab washer
(4) Tapered roller bearing (13) Threaded ring on the lock side
(5) Bearing shell mounting bolt (14) Crown wheel mounting bolt
(6) Oil baffle (15) Axle drive housing
(7) Differential
(8) Thrust washer
(9) Crown wheel
G5 7 - 133
AXLE DRIVE
Technical data
Bearing shell mounting bolts (5) ............................ M16x1.5x95-10.9 ..................................... 290 ± 10 Nm
mounting bolts (4)................................................. M8x35-8.8 .........................................................22 Nm
Tab washer mounting bolt (12) .............................. M8x16-10.9 .......................................................35 Nm
Backlash when crown wheel Ø is 233 mm (9) .......................................................................0.20-0.30 mm
Bearing preload........................................................................................................................ 75 ± 5 Nm
Fitted washers............................................................................................................................0.5/1 mm
Selector shaft axial play ................................................................................................................ 0.5 mm
Service products
Marking paste ................................................................................................................... 04.10349-9701
Optimol White-T assembly paste ........................................................................................ 09.15011-0007
Note
Always replace the entire gear set (i.e. the crown wheel and the drive pinion) when replacing the
crown wheel or the drive pinion.
Special tools
[83] Dial gauge 08.71000-3217
• Checking the backlash in conjunction with:

• Checking the backlash in conjunction with:

• Dial gauge [83]
[85] Lifting device 80.99606-6116
• Removing and installing the differential in

conjunction with:
• Insertable discs [86]
[86] Insertable discs 80.99606-0578
• Removing and installing the differential in

conjunction with:
• Lifting device [85]
• Screwing in the threaded ring
7 - 134 G5
AXLE DRIVE
• Screwing in the threaded ring
[89] Fixing clamp 80.99622-0055
• Setting the bearing preload
[90] Test pads 80.99607-0171
• Checking the fixing clamp
• Blocking the differential lock
• Removing the selector shaft in conjunction with:

• Adapter [93]
• Adapter M12x1.5/M14x1.5 [94]
[93] Adapter 80.99602-0140

• Adapter M12x1.5/M14x1.5 [94]
[94] Adapter M12x1.5/M14x1.5 80.99602-0138

• Adapter [93]
[95] Support handle 80.99617-0005
• Installing the selector shaft in conjunction with:

• Stud bolt [96]
G5 7 - 135
AXLE DRIVE
[96] Stud bolt 06.06138-0712

• Support handle [95]
[97] Turning device 80.99606-6130
• Clamping the axle drive
7 - 136 G5
AXLE DRIVE
Removing the differential Removing the lock components
• Remove the sliding sleeve (2) from the selector

fork (3)
• Unscrew the Pressure spindle [91] (3) • Remove the selector fork (3) with pressure spring
• Unscrew the mounting bolts (2) for the selector (1) from the axle drive
cylinder cover (4)
• Remove the selector cylinder cover (4) with gasket Removing the bearing shell
(1)
Removing the selector shaft
• Remove the retainer (2) for the threaded ring (4)

• Unscrew the mounting bolts (3) for the bearing
shell (1)
• Extract the selector shaft (1) using the Impact • Remove the threaded ring (4) with the bearing
extractor [92] (3), the Adapter M12x1.5/M14x1.5 shell (1)
[94] and the Adapter [93] (2)
Unscrewing the threaded ring
• Remove the retainer (2) for the threaded ring (3)
G5 7 - 137
AXLE DRIVE
• Unscrew the mounting bolts (1) for the bearing Installing the differential
shell
• Remove the bearing shell with the threaded ring Inserting the differential
(3)
Lifting out the differential
• Insert the Lifting device [85] (1) into the differential

in conjunction with the Insertable discs [86]
• Insert the differential with bearing outer races into
• Insert the axle drive into the Turning device [97] the axle drive housing
• Insert the Lifting device [85] (1) into the differential
in conjunction with the Insertable discs [86] Fitting the bearing shells
• Lift the differential with bearing outer races out of
the axle drive housing
• Fit the bearing shells (1) and (2)

so that the threaded rings (4) can still be turned
• Screw the threaded ring (4) into the bearing shell
(1)
7 - 138 G5
AXLE DRIVE
Preloading the tapered roller bearing Setting the differential
Adjusting the backlash
• Screw the threaded ring (2) into the bearing shell

• Tighten the mounting bolts (1) for both bearing
shells to 290 ± 10 Nm Note
• Alternately screw the threaded ring (2) into the Measure the backlash at three points that
bearing shell whilst turning on the crown wheel are each 120° apart.
until the tapered roller bearings have a slight
preload
• Place the Dial gauge holder [84] with Dial gauge
[83] (1) on the axle drive housing
• Locate the measuring tip of Dial gauge [83] (1) at
right angles to the outer area of the tooth flank
• Block the drive pinion
• Measure the backlash by turning the crown wheel
in the opposite direction
• By turning the threaded rings alternately using
Grooved nut spanner socket [87] and Grooved
nut spanner socket [88] , move the crown wheel
towards the drive pinion until a backlash of
0.20-0.30 mm has been obtained
Mounting the fixing clamp
Note
Insert the Fixing clamp [89] (1) for
checking the dimensional accuracy
with the Test pads [90] into the centring
holes in the axle drive housing in the axle
housing, renewing Fixing clamp [89] (1)
as necessary.
G5 7 - 139
AXLE DRIVE
• To set the bearing preload, place the Fixing clamp Securing the threaded rings
[89] (1) on the centring journal of the bearing shells
(2)
Setting the bearing preload
• Mount the threaded ring retainer (1) and tighten

the mounting bolt to 35 Nm
Installing the lock components
Note
When tightening the threaded rings, strike
the bearing shells several times with a
soft hammer in order to ensure that the
bearings are correctly seated.
The bearing preload must remain after
the bearing shell has been tightened.
• Use the Grooved nut spanner socket [87] (4) to

tighten the threaded ring on the crown wheel side
to 75 ± 5 Nm whilst turning the crown wheel (1)
• Measure the backlash again to check it and then
re-adjust it as necessary
• Remove the Fixing clamp [89]
• Insert the sliding sleeve (2), selector fork (3) and
Securing the threaded ring on the lock side pressure spring (1) into the axle drive housing
• Mount the threaded ring retainer (1) and tighten

the mounting bolt to 35 Nm
7 - 140 G5
AXLE DRIVE
Installing the selector shaft • Screw in the mounting bolts (2) for the selector
cylinder cover (4) and tighten them to 22 Nm
• Lock the transverse differential lock by screwing
cylinder cover (4)
• Engage the sliding sleeve teeth in the crown wheel
teeth
• Remove the axle drive from the Turning device
[97]
Note
The fitted washers are available in
thickness sizes of 0.5 or 1 mm.
Select fitted washers (1) that ensure
an axial play of 0.5 mm between the
locking components, see Adjusting the
transverse differential lock, 8-178.
• Mount the Support handle [95] on the selector

shaft (2) with the Stud bolt [96]
• Place a 0.5 mm or 1 mm fitted washer (1) on the
selector shaft (2)
• Fit a new O-ring onto the selector shaft (2)
• Apply Optimol White-T assembly paste on the
contact surface of the selector shaft (2)
• Use the Support handle [95] to insert the selector
shaft (2) through the selector fork and the pressure
spring and into the shaft duct
Installing the selector cylinder cover
Note
Note the installation position of the gasket
for the selector cylinder cover (4).
Install the gasket for the selector cylinder
cover (4) with the black side facing the
cover.
• Fit the selector cylinder cover (4) with a new gasket

(1) and position it
G5 7 - 141
AXLE DRIVE
Contact pattern check Adjusting the contact pattern
Correct contact pattern on crown wheel
• If there is contact on the tooth tip, reduce

the installation depth of the drive pinion
Note by using thinner shims, see Removing and
Check the contact pattern on the crown installing/adjusting the drive pinion housing, 7-155
wheel in order to determine whether there • To ensure that the correct backlash is maintained,
are any crown wheel and drive pinion increase the crown wheel installation distance by
setting errors evenly turning the threaded rings, see Adjusting
the backlash, 7-139
• Apply Marking paste on both sides of three crown
wheel teeth spaced 120° apart Contact on tooth root
• Alternately turn the crown wheel back and forth by
hand
• Check the contact pattern
The contact pattern is correct if the outside edge is
not touched at any point on the tooth surface
Contact on tooth tip
• Check the contact pattern on the tooth root

Contact on tooth root = inadequate meshing
• Check the contact pattern

Contact on tooth tip = excessive meshing
7 - 142 G5
AXLE DRIVE
Adjusting the contact pattern
• If there is contact on the tooth root, increase

the installation depth of the drive pinion
by using thicker shims, see Removing and
installing/adjusting the drive pinion housing, 7-155
• To ensure that the correct backlash is maintained,
reduce the crown wheel installation distance by
evenly turning the threaded rings, see Adjusting
the backlash, 7-139
G5 7 - 143
AXLE DRIVE
Dismantling and assembling the differential
Includes
Removing and installing/adjusting the differential, see 7-133
(1) Threaded ring (11) Bearing shell

(2) Oil baffle (12) Tab washer
(3) Bearing shell (13) Threaded ring on the lock side
(4) Tapered roller bearing (14) Crown wheel mounting bolt
(5) Bearing shell mounting bolt (15) Axle drive housing
(6) Oil baffle
(7) Differential
(8) Thrust washer
(9) Crown wheel
(10) Tapered roller bearing
7 - 144 G5
AXLE DRIVE
Technical data
Crown wheel mounting bolts on differential housing
(14)...................................................................... M14x1.5x50-12.9 ........................... Initial torque 50 Nm
Crown wheel mounting bolts on differential housing
(14)...................................................................... M14x1.5x50-12.9 .................................Final torque 90°
Differential pin locking bolt .................................... M10x110-10.9-black ...........................................65 Nm
Differential pin locking bolt .................................... M10x110-10.9-silver/grey....................................50 Nm
Installation temperature for bearings (4) and (10) ............................................................................ 130 °C
Installation temperature for crown wheel (9) .................................................................................... 100 °C
Note
Always replace side gears and differential pinions as a set.
Special tools
[98] Extractor 08.99605-9012
• Removing the tapered roller bearing on the crown

wheel side in conjunction with:
• Splitter blades [99]
[99] Splitter blades 08.99605-9002

• Extractor [98]
[100] Thrust piece 80.99609-0012

• Extractor [98]
• Splitter blades [99]
• Removing the tapered roller bearing on the

differential side in conjunction with:
[102] Thrust piece 80.99609-0013

G5 7 - 145
AXLE DRIVE
[103] Quick gripper 80.99628-0074

[104] Removal sleeve 80.99601-0167

[105] Plug-on handle 80.99617-0188
• Pressing off the crown wheel in conjunction with:

• Washer [106]
[106] Washer 80.99617-0144

[107] Pressing tool 80.99614-0018

• Washer [106]
[108] Aligning tools 80.99617-0163
• Fitting the crown wheel
[109] Socket, size 22 80.99612-0024
• Tightening crown wheel bolts in conjunction with:

• Torque multiplier i = 1:3.3 [111]
• Holding device [114]
• Support [112]
• Cheese-head screw [115]
• Washer [118]
• Socket E18 [110]
• Torque angle gauge [113]
• Socket, size 22 [109]
• Connecting pin [116]
• Rubber ring 42 mm [117]
• Crown wheel assembly device [119]
7 - 146 G5
AXLE DRIVE
[110] Socket E18 80.99612-0023

• Support [112]
• Washer [118]
[111] Torque multiplier i = 1:3.3 80.99619-0006

• Support [112]
• Washer [118]
• Socket E18 [110]
[112] Support 80.99606-0551

• Washer [118]
• Socket E18 [110]
[113] Torque angle gauge 80.99607-0172

• Support [112]
• Washer [118]
• Socket E18 [110]
G5 7 - 147
AXLE DRIVE
[114] Holding device 80.99606-0553

• Support [112]
• Washer [118]
• Socket E18 [110]
[115] Cheese-head screw 06.02191-0407

• Support [112]
• Washer [118]
• Socket E18 [110]
[116] Connecting pin 06.22729-0006

• Support [112]
• Washer [118]
• Socket E18 [110]
[117] Rubber ring 42 mm 08.06142-9006

• Support [112]
• Washer [118]
• Socket E18 [110]
7 - 148 G5
AXLE DRIVE
[118] Washer 80.99609-0033

• Support [112]
• Socket E18 [110]
[119] Crown wheel assembly device 80.99606-6132

• Support [112]
• Socket E18 [110]
• Washer [118]
G5 7 - 149
AXLE DRIVE
Dismantling the differential Extracting the tapered roller bearing on the

differential side
Extracting the tapered roller bearing on the
crown wheel side
• Insert the Thrust piece [100] (3)

• Mount the Splitter blades [99] (1) below the
tapered roller bearing (2)
• Mount the Extractor [98] (4) onto the Splitter
blades [99] (1) and extract the tapered roller
bearing (2) by screwing in the spindle
Note
The Removing device [101] (4) is a
hydraulic spindle. The maximum travel
achievable in one action for pulling off
the tapered roller bearing is limited to 30
mm (piston stroke). After a distance of
30 mm, relieve the load on the hydraulic
spindle and turn the large spindle by the
same amount. Then repeat the pulling-off
process.
• Insert the Thrust piece [102] (1) into the shaft duct
• Place the Quick gripper [103] (2) onto the tapered
roller bearing (5) and clamp it
• Mount the Removal sleeve [104] (3) with
Removing device [101] (4) on the Quick gripper
[103] (2)
• Remove the tapered roller bearing (5) from the
differential housing using the hydraulic spindle
• Remove the differential housing oil baffle
7 - 150 G5
AXLE DRIVE
Assembling the special tool • Clamp the Crown wheel assembly device [119] (1)
in a vice
• Place the differential on the aligning tool on the
Crown wheel assembly device [119] (1)
• Select a counter-holder that is suitable for
the differential lock teeth and insert it into the
differential lock teeth
• Position the assembled special tool (2) on the
mounting bolt (3) to be undone
• Undo all the mounting bolts (3) and then unscrew
and remove them all with the exception of two
opposite-facing mounting bolts (3)
Pressing off the crown wheel
• Fit the Holding device [114] (5) with Cheese-head

screw [115] (4) and Washer [118] (3) on the
Support [112] (2)
• Insert the Torque multiplier i = 1:3.3 [111] (1) into
the Support [112] (2)
• Place the Torque angle gauge [113] (11) onto the
Torque multiplier i = 1:3.3 [111] (1)
• Place Socket, size 22 [109] (9) on Torque multiplier
i = 1:3.3 [111] (1) and secure using Connecting pin
[116] (10) and Rubber ring 42 mm [117] (8)
• Insert the Socket E18 [110] (6) into the Holding
device [114] (5) • Secure the component to prevent it from dropping
• Insert the Socket E18 [110] (6) into the Socket, down
size 22 [109] (9) • Insert the differential into the hydraulic press
• Insert the Pressing tool [107] with Plug-on handle
Unscrewing the crown wheel mounting bolts [105] and Washer [106] into the shaft duct
• Secure the differential housing to prevent it from
falling
• Unscrew the remaining crown wheel mounting
bolts
• Use the hydraulic press to press off the differential
housing crown wheel (1)
Removing the upper side gear
CAUTION
Danger of injury due to heavy
components
• Use lifting device
Note
Note the torque multiplier ratio, i = 1 : 3.3.
• Remove the upper side gear (2) and thrust washer

• Place an aligning tool suitable for the size of the (3) from the differential housing (1)
differential on the Crown wheel assembly device
[119]
G5 7 - 151
AXLE DRIVE
Removing the differential pinions Assembling the differential
Installing the lower side gear
• Unscrew the locking bolt (4) from the differential

pins (1) and (3)
• Remove the short differential pin (3) and long • Apply a thin coat of oil on all contact faces, thrust
differential pin (1) from the differential housing washers and tooth flanks before assembly
• Remove the differential pinions (2) and the • Insert the lower side gear (1) and thrust washer
spherical washers from the differential housing (2) into the differential housing
Removing the lower side gear Installing the differential pinions
• Remove the lower side gear (1) and thrust washer Note
(2) from the differential housing Always renew bolts and nuts.
• Check the side gears, differential pinions and pins The locking bolt (4) is available in
for wear and replace them as a set if necessary two different colours with two different
tightening torques.
Black locking bolt: Tightening torque 65
Nm
Silver/grey locking bolt: Tightening torque
50 Nm
• Insert the differential pinions (2) into the differential

housing with the spherical washers
• Insert the long differential pin (1) through the
spherical washers and the differential pinions (1)
and into the differential housing
• Insert both the short differential pins (3) into the
differential housing
• Screw in a new locking bolt (4) for the differential
pins (1) and (3) and tighten them to 65 Nm and 50
Nm respectively
7 - 152 G5
AXLE DRIVE
Installing the upper side gear Tightening the crown wheel
• Insert the upper side gear (2) and thrust washer CAUTION
(3) into the differential housing (1) Danger of injury due to heavy
• Check that the differential pinions and side gears differential
turn smoothly • Use lifting device
Fitting the crown wheel Note
Note the torque multiplier ratio, i = 1 : 3.3.
• Place the differential on the aligning tool on the

Crown wheel assembly device [119] (1)
• Select a counter-holder that is suitable for
the differential lock teeth and insert it into the
differential lock teeth
• Position the assembled special tool (2) on the
mounting bolt (3) to be tightened
• Tighten the mounting bolts (3) to Initial
torque 50 Nm
• Tighten the mounting bolts (3) to Final torque 90°
• Remove the differential
CAUTION
components
Note
Always renew bolts and nuts
• Screw two Aligning tools [108] into the differential

housing (1)
• Heat the crown wheel to 100 °C
• Fit the crown wheel (2) over the Aligning tools [108]
and onto the differential housing (1)
• Screw in new mounting bolts and tighten them by
hand
G5 7 - 153
AXLE DRIVE
Fitting the tapered roller bearing on the crown • Heat the tapered roller bearing on the differential
wheel side side to 130 °C
• Fit the tapered roller bearing onto the differential
housing, pressing it as far as the stop and seating
it as necessary
CAUTION
components
Note
Use new tapered roller bearings as
supplied, i.e. do not apply oil or grease.
• Heat the tapered roller bearing on the crown wheel

side to 130 °C
• Fit the tapered roller bearing onto the crown wheel,
pressing it as far as the stop and seating it as
necessary
Fitting the tapered roller bearing on the

differential side
CAUTION
components
Note
Use new tapered roller bearings as
supplied, i.e. do not apply oil or grease.
• Place the oil baffle on the differential housing
7 - 154 G5
AXLE DRIVE
DRIVE PINION
Removing and installing/adjusting the drive pinion housing
Includes
(1) Drive pinion housing mounting bolt (4) Axle drive housing
(2) Drive pinion housing (5) Sealing ring
(3) Drive pinion housing seal (6) Drive pinion housing mounting bolt
Technical data
Drive pinion housing mounting bolts (1) ................. M14x1.5x40-10.9-black ............................ 185 ± 10 Nm
Drive pinion housing mounting bolts (1) ................. M14x1.5x40-10.9-silver/grey.............................162 Nm
G5 7 - 155
AXLE DRIVE
Drive pinion housing mounting bolts (6) ................. M14x1.5x40-10.9-silver/grey..................... 185 ± 10 Nm
Service products
Note
After changing the pinion bearings, the crown wheel/drive pinion or the drive pinion housing, the
installation depth of the drive pinion and the thickness of the shims has to be calculated again.
Special tools
[120] Suspension device 80.99622-0034
• Removing and installing the drive pinion housing
[121] Depth gauge (electronic) 08.71195-9003
• Determining the installation depth of the drive

pinion housing
[122] Clamping plate 80.99613-0003
• Removing and installing the drive pinion housing
7 - 156 G5
AXLE DRIVE
Removing the drive pinion housing Installing the drive pinion housing
Drive pinion housing with sealing rings
Note
Drive pinion housings with and without
sealing rings (5) are installed. WARNING
Leaks due to incorrect mounting bolts
• If the sealing rings (5) cannot
• Clamp the axle drive on the Clamping plate [122]
be replaced, the corresponding
• Mark the position of the drive pinion housing (3)
mounting bolts must be replaced by
relative to the axle drive housing (1)
micro-encapsulated bolts
• Unscrew the mounting bolts (4) for the drive pinion
• Note the different torque when using
housing (3)
micro-encapsulated bolts
• Attach the Suspension device [120] to the input
flange and remove the drive pinion housing (3) Note
• Mark the installation position of the shims (2) and If several shims are fitted, apply a light
then remove the shims coating of Omnifit FD 3041 face sealing
• Extract the sealing rings (5) from the agent between the shims.
through-bores in the axle drive housing
(1) • Insertnew sealing rings (5) into the drive pinion
• Clean the sealing surfaces housing (3)
• Apply a thin coat of Omnifit FD 3041 face sealing
agent on the sealing surfaces
• Place the shims (2) onto the axle drive housing in
their correct installation positions
• Insert the drive pinion housing (3) into the axle
drive housing as marked
• Screw in new mounting bolts (4) and tighten to
185 ± 10 Nm
• Remove the axle drive from the Clamping plate
[122]
G5 7 - 157
AXLE DRIVE
Drive pinion housing without sealing rings Determining the installation depth of the drive
pinion housing
Determining dimension "A"
• Use Depth gauge (electronic) [121] to determine

dimension "A"= distance between the end face of
the drive pinion (1) and the centre of the crown
wheel bearing seat
Determining the shim thickness (dimension "S")
Note
If several shims are fitted, apply a light
coating of Omnifit FD 3041 face sealing
agent between the shims.
• Insertnew sealing rings (5) into the drive pinion

housing (3)
• Apply a thin coat of Omnifit FD 3041 face sealing
• Place the shims (2) onto the axle drive housing in
their correct installation positions
• Insert the drive pinion housing (3) into the axle Note
drive housing as marked If dimension "S" is not equal to 0, repeat
• Screw in the new mounting bolts (4) the removal and installation process and
• Tighten nine mounting bolts in the blind holes to insert the correct shims.
162 Nm
• Determine dimension "S"
• Tighten the three mounting bolts (4) in the
Dimension "S" is equal to dimension "A" minus
through-bores on the axle drive to 185 ± 10 Nm
dimension "C".
[122] Reference dimension "C" is fixed. It is indicated on
the end face of the drive pinion or on the back of the
crown wheel. After adjustment, dimension "A" must
be equal to reference dimension "C".
Example: Dimension "A" = 107.4 mm minus

dimension "C" = 105.42 mm equals dimension "S"
= 1.98 mm. Use suitable shims with total thickness
of 2.0 mm.
7 - 158 G5
AXLE DRIVE
Dismantling and assembling the drive pinion housing
Includes
Removing and installing/adjusting the drive pinion housing, see 7-155
(1) Bi-hexagonal nut (7) Drive pinion housing

(2) Input flange (8) Drive pinion housing seal
(3) Rotary shaft seal (9) Oil baffle
(4) Outer tapered roller bearing (10) Inner bearing outer race
(5) Outer bearing outer race (11) Inner tapered roller bearing
(6) Fitted washer (12) Drive pinion
Technical data
Bi-hexagonal nut (1) ............................................. M45x1.5 .................................................. 950 ± 50 Nm
G5 7 - 159
AXLE DRIVE
Drive pinion housing mounting bolts (7) ................. M14x1.5x40-10.9-silver/grey.............................162 Nm
Drive pinion housing mounting bolts (7) ................. M14x1.5x40-10.9-silver/grey..................... 185 ± 10 Nm
Installation temperature for tapered roller bearings (4) and (11) ........................................................ 130 °C
Dimension C ...........................................................................................................................0.2-0.3 mm
Friction torque for drive pinion tapered roller bearing ...................................................................... 2-3 Nm
Fitted washers for setting coefficient of friction (in 0.01 mm steps)..........................................3.50-5.30 mm
Service products
Special tools
[123] Socket 80.99603-0175

[124] Torque multiplier i = 1:8 83.09195-6001

• Socket [123]
[125] Adapter flange 80.99610-0009

• Socket [123]
[126] Torque wrench with follow-up pointer 80.99619-0005
• Checking the friction coefficient in conjunction

with:
• 1" adapter [127]
• Socket for bi-hexagonal nut [128]
[127] 1" adapter 80.99607-6024

with:
• Torque wrench with follow-up pointer [126]
• Socket for bi-hexagonal nut [128]
[128] Socket for bi-hexagonal nut 08.06142-2639

with:
• Torque wrench with follow-up pointer [126]
• 1" adapter [127]
7 - 160 G5
AXLE DRIVE
• Extracting the bearing outer race in conjunction

with:
[130] Extractor hook 8099602-0137
• Extracting the bearing outer race in conjunction

with:
[131] Press plate 80.99614-0004

conjunction with:
• Washer [135]
[132] Press plate 80.99614-0025
• Installing the outer bearing outer race in

conjunction with:
• Washer [135]
[133] Press plate 80.99604-0079
• Pressing in the oil baffle in conjunction with:

• Washer [135]
[134] Plug-on handle 80.99617-0188
• Pressing in the oil baffle

conjunction with:
• Washer [135]
• Press plate [133]
[135] Washer 80.99617-0144
• Pressing in the oil baffle

• Outer bearing outer race
conjunction with:
G5 7 - 161
AXLE DRIVE
[136] Quick gripper 80.99628-0083
• Removing the tapered roller bearing in

conjunction with:
• Sleeve [137]
[137] Sleeve 80.99601-0169

conjunction with:

conjunction with:
• Sleeve [137]
[139] Clamping plate 80.99613-0004
• Clamping the pinion housing
[140] Suspension device 80.99622-0034
• Removing the drive pinion housing
[141] Depth gauge (electronic) 08.71195-9003
• Determining the installation depth of the drive

pinion housing
7 - 162 G5
AXLE DRIVE
Dismantling the drive pinion/drive pinion Releasing the bi-hexagonal nut

housing
Removing the drive pinion housing
• Release the bi-hexagonal nut (1) (groove must be

free)
Unscrewing the bi-hexagonal nut
Note
Drive pinion housings with and without
sealing rings (5) are installed.
• Clamp the axle drive on the Clamping plate [139]

• Mark the position of the drive pinion housing (3) in
relation to the axle drive housing
• Unscrew the mounting bolts (4) for the drive pinion
housing (3)
• Attach the Suspension device [140] to the input
flange and remove the drive pinion housing (3)
• Mark the installation position of the shims (2) and
then remove the shims
• Extract the sealing rings (5) from the
through-bores in the axle drive housing
(1) • Place the Socket [123] (2) on the bi-hexagonal nut
• Clean the sealing surfaces (1)
• Mount the Adapter flange [125] (3) on the Torque
multiplier i = 1:8 [124] (4)
• Mount the Torque multiplier i = 1:8 [124] (4) with
the Adapter flange [125] (3) on the input flange
• Unscrew the bi-hexagonal nut (1)
• Pull off the input flange, see Removing the input
flange, 7-122
• Remove the rotary shaft seal, see Removing the
rotary shaft seal, 7-122
G5 7 - 163
AXLE DRIVE
Pressing out the drive pinion Extracting the outer bearing outer race
• Secure the component to prevent it from dropping • Extract the outer bearing outer race (1) from the
down drive pinion housing (2) using the Impact extractor
• Remove the fitted washer from the drive pinion [129] in conjunction with the Extractor hook [130]
• Mount the drive pinion housing (2) on the
Clamping plate [139] (1) Extracting the inner bearing outer race
• Press out the drive pinion (3) and remove the
tapered roller bearing
Removing the tapered roller bearing
• Extract the inner bearing outer race (1) from the

drive pinion housing (2) using the Impact extractor
[129] in conjunction with the Extractor hook [130]
• Remove the tapered roller bearing (2) from the Extracting the oil baffle
drive pinion housing (1)
• Extract the oil baffle (1) from the drive pinion

housing using the Impact extractor [129] in
conjunction with the Extractor hook [130]
7 - 164 G5
AXLE DRIVE
Removing the inner tapered roller bearing Assembling the drive pinion/drive pinion
housing
Pressing in the oil baffle
• Assemble the installer sleeve consisting of the

Washer [135] , the Plug-on handle [134] (3) and
the Press plate [133] (2)
• Place the angled side of the oil baffle (1) on the
Press plate [133]
• Press the oil baffle (1) into the drive pinion housing
(4) until the stop is reached using the installer
sleeve
Installing the inner bearing outer race

• Assemble the extractor tool consisting of the Quick
gripper [136] (2), the Sleeve [137] (3) and the
Removing device [138] (4)
• Place the extractor tool over the tapered roller
bearing (1) and clamp by fitting the clamping
sleeve of the Quick gripper [136] (2)
• Remove the tapered roller bearing (1)

• Press the inner bearing outer race (1) into the drive
pinion housing (4) until the stop is reached using
the installer sleeve
G5 7 - 165
AXLE DRIVE
Installing the outer bearing outer race Determining dimension "A"

• Press the outer bearing outer race (1) into the drive
pinion housing (4) until the stop is reached using
the installer sleeve
Inserting the outer tapered roller bearing
• Insert the inner tapered roller bearing (2) into the

drive pinion housing
• Use the Depth gauge (electronic) [141] (1) to
determine dimension A between the outer end
face of the inner tapered roller bearing (2) and the
inner end face of the outer tapered roller bearing
(3)
Determining the fitted washer thickness

• Insert the outer tapered roller bearing (1) into the
drive pinion housing (2)
• Place the outer tapered roller bearing (1) with drive
pinion housing (2) on the input flange (3)
• Determine dimension B using Depth gauge

(electronic) [141]
• Determine the fitted washer thickness (dimension
C) by subtracting dimension B from dimension A
• In order to achieve the required drive pinion
tapered roller bearing friction torque of 2-3 Nm ,
0.2-0.3 mm must be subtracted from dimension C
7 - 166 G5
AXLE DRIVE
Mounting the inner tapered roller bearing Assembling the drive pinion/drive pinion
housing
CAUTION
components
• Heat the inner tapered roller bearing (1) to 130 °C

• Mount the inner tapered roller bearing (1) on the
drive pinion, making sure that the stop is reached,
and seat it as necessary
CAUTION
components
• Insert the drive pinion (1) into the drive pinion

housing (2)
• Turn over the drive pinion (1) with drive pinion
housing (2)
• Mount the fitted washer (3) with the chamfer facing
the drive pinion (1)
• Heat the outer tapered roller bearing (4) to 130 °C
• Fit the outer tapered roller bearing (4) on the drive
pinion (1) and seat it as necessary
• Install the rotary shaft seal
G5 7 - 167
AXLE DRIVE
Setting the friction coefficient Fitting the torque wrench
Mounting the input flange
• Place the Socket for bi-hexagonal nut [128] (2) on

the bi-hexagonal nut
• Fit the 1" adapter [127] and the Torque wrench
with follow-up pointer [126] with the socket (1) on
the bi-hexagonal nut
Determining the friction coefficient
Note
Do not install the rotary shaft seal when
measuring the friction coefficient.
After setting the friction coefficient,
remove the input flange and install the
rotary shaft seal, see Pressing in the
rotary shaft seal, 7-123 Note
If the calculated friction coefficient is out
• Place the input flange on the drive pinion of tolerance, repeat the removal and
• Screw on the bi-hexagonal nut (1) and tighten it by installation process and insert the correct
hand fitted washer.
• Place the Socket [123] (2) on the bi-hexagonal nut Thicker fitted washer = lower friction
(1) coefficient.
• Mount the Adapter flange [125] (3) on the Torque Thinner fitted washer = higher friction
multiplier i = 1:8 [124] (4) coefficient.
• Mount the Torque multiplier i = 1:8 [124] (4) with Fitted washers are available in thickness
the Adapter flange [125] (3) on the input flange sizes of 3.50-5.30 mm in 0.01 mm steps.
• Tighten the bi-hexagonal nut (1) to 950 ± 50 Nm
• Zero the Torque wrench with follow-up pointer
[126]
• Overcome the drive pinion release torque and
read off the friction coefficient whilst the pinion is
turning constantly in clockwise direction
• The friction coefficient must be 2-3 Nm
• Remove the input flange and install the rotary shaft
seal, see Removing and installing the drive shaft
rotary shaft seal, 7-119
7 - 168 G5
AXLE DRIVE
Drive pinion housing with sealing rings Drive pinion housing without sealing rings
WARNING Note
Leaks due to incorrect mounting bolts If several shims are fitted, apply a light
• If the sealing rings (5) cannot coating of Omnifit FD 3041 face sealing
be replaced, the corresponding agent between the shims.
mounting bolts must be replaced by
micro-encapsulated bolts • Insertnew sealing rings (5) into the drive pinion
• Note the different torque when using housing (3)
micro-encapsulated bolts • Apply a thin coat of Omnifit FD 3041 face sealing
Note • Place the shims (2) onto the axle drive housing in
If several shims are fitted, apply a light their correct installation positions
coating of Omnifit FD 3041 face sealing • Insert the drive pinion housing (3) into the axle
agent between the shims. drive housing as marked
• Screw in the new mounting bolts (4)
• Insertnew sealing rings (5) into the drive pinion • Tighten nine mounting bolts in the blind holes to
housing (3) 162 Nm
• Apply a thin coat of Omnifit FD 3041 face sealing • Tighten the three mounting bolts (4) in the
agent on the sealing surfaces through-bores on the axle drive to 185 ± 10 Nm
• Place the shims (2) onto the axle drive housing in • Remove the axle drive from the Clamping plate
their correct installation positions [122]
• Insert the drive pinion housing (3) into the axle
drive housing as marked
• Screw in new mounting bolts (4) and tighten to
185 ± 10 Nm
[122]
G5 7 - 169
TRANSVERSE DIFFERENTIAL LOCK
(1) Axle drive (8) Pressure switch

(2) Sliding sleeve (9) Selector cylinder cover seal
(3) Double-joint shaft (10) Bearing bush
(4) Selector fork (11) O-ring
(5) Pressure spring (12) Selector shaft
(6) Selector cylinder cover (13) Fitted washer
(7) Sealing ring
G5 8 - 171
Removing and installing the transverse differential lock
Includes
(1) Axle drive (10) Bearing bush

(2) Sliding sleeve (11) O-ring
(3) Double-joint shaft (12) Selector shaft
(4) Selector fork (13) Fitted washer
(5) Pressure spring
(6) Selector cylinder cover
(7) Sealing ring
(8) Pressure switch
(9) Selector cylinder cover seal
G5 8 - 173
Technical data
mounting bolts (4)................................................. M8x35-8.8 .........................................................22 Nm
Axial play on locking components if 1.0-mm gauge used................................................................. 0.5 mm
Fitted washer thickness .................................................................................................... 0.5 mm/1.0 mm
Service products
Optimol White-T assembly paste ........................................................................................ 09.15011-0007
Special tools

• Adapter [143]
• Adapter M12x1.5/M14x1.5 [144]
[143] Adapter 80.99602-0140

• Adapter M12x1.5/M14x1.5 [144]
[144] Adapter M12x1.5/M14x1.5 80.99602-0138

• Adapter [143]
[145] Plug-on handle 80.99617-0188
• Installing the bearing bush in conjunction with:

• Washer [146]
• Support [148]
[146] Washer 80.99617-0144

• Support [148]
[147] Pressing tool 80.99617-0161

• Washer [146]
8 - 174 G5
[148] Support 08.99615-0015
• Removing the bearing bush in conjunction with:

• Internal extractor [149]
[149] Internal extractor 08.99615-2810
• Removing the bearing bush in conjunction with:

• Support [148]
[150] Feeler gauge 08.75310-0806
• Checking the axial play on the transverse

differential lock
• Blocking the transverse differential lock
[152] Support handle 80.99617-0005

• Stud bolt [153]
[153] Stud bolt 06.06138-0712

• Support handle [152]
G5 8 - 175
Removing the transverse differential lock Removing the lock components
• Remove the sliding sleeve (2) from the selector

fork (3)
• Unscrew the Pressure spindle [151] (3) • Remove the selector fork (3) with pressure spring
• Unscrew the mounting bolts (2) for the selector (1) from the axle drive
cylinder cover (4)
• Remove the selector cylinder cover (4) with seal Removing the bearing bush
(1)
Removing the selector shaft
• Extract the bearing bush (1) using the Internal

extractor [149] (2) and the Support [148] (3)
• Extract the selector shaft (1) using the Impact

extractor [142] (3), the Adapter M12x1.5/M14x1.5
[144] and the Adapter [143] (2)
8 - 176 G5
Installing the transverse differential lock Installing the selector shaft
Pressing in the bearing bush
Note
• Press the bearing bush (1) into the axle drive The fitted washers are available in
housing using the Pressing tool [147] (2) and thickness sizes of 0.5 mm/1.0 mm .
Plug-on handle [145] (3) with Washer [146] (4) Select fitted washers (1) and thickness
• Apply Optimol White-T assembly paste on the sizes that ensure an axial play of 0.5 mm
bearing bush contact surface between the locking components, see
Adjusting the transverse differential lock,
Installing the lock components 8-178.
• Mount the Support handle [152] with Stud bolt

[153] on the selector shaft
• Place the 0.5 mm/1.0 mm fitted washer (1) on the
selector shaft (2)
• Fit a new O-ring onto the selector shaft (2)
• Apply Optimol White-T assembly paste on the
contact surface of the selector shaft (2)
• Insert the selector shaft (2) through the selector
fork and the pressure spring and into the shaft
duct
• Position the selector fork (3) with pressure spring

(1) on the pressure spring guide in the axle drive
• Use the selector fork (3) to compress the pressure
spring (1) and insert it into the axle drive
• Insert the sliding sleeve (2) into the selector fork
(3) with the locking teeth facing the crown wheel
G5 8 - 177
Adjusting the transverse differential lock • Lock the transverse differential lock by screwing
Checking the axial play cylinder cover (3)
• Engage the sliding sleeve teeth in the crown wheel
teeth
Note
If the axial play measured between the
selector fork and the sliding sleeve is 1
mm, the axial play on the end face of the
teeth between the sliding sleeve and the
selector fork is 0.5 mm .
• With the differential lock engaged, use a 1.0-mm

Feeler gauge [150] to measure the axial play
between the selector fork and the sliding
sleeve. Re-adjust using a suitable fitted washer
if necessary.
Installing the selector cylinder cover
Note
Note the installation position of the seal
(1) for the selector cylinder cover (4).
The seal (1) for the selector cylinder cover
(4) must always be installed with the black
side facing the cover.
• Fit the selector cylinder cover (4) with a new seal

(1) and position it
• Screw in the mounting bolts (2) for the selector
cylinder cover (3) and tighten them to 22 Nm
8 - 178 G5
TRACK ROD/STEERING ARM
(1) Steering knuckle arm, left (4) Steering knuckle arm, right
(2) External hexagonal round screw, steering (5) Lock nut, track rod
arm (6) Track rod
(3) Steering arm
G5 9 - 179
Removing and installing the track rod/steering arm
Includes
(1) Steering knuckle arm, left (4) Clamp, track rod

(2) Steering arm (5) Track rod
(3) Steering knuckle arm, right (6) Lock nut, track rod
Technical data
Track rod lock nut (5) ............................................ M24x1.5 .................................................. 300 ± 30 Nm
Clamp mounting bolt (2)........................................ M14x1.5x80-10.9 .................................... 160 - 180 Nm
External hexagonal round screws, steering arm(4) .. M16x1.5x55-10.9 ..................................... 310 ± 30 Nm
External hexagonal round screws, steering arm(4) .. M16x1.5x70-10.9 ..................................... 310 ± 30 Nm
Maximum permitted ball joint play.............................................................................................max. 2 mm
Service products
DS1KG high-temperature paste ......................................................................................... 09.16012-0115
G5 9 - 181
WARNING
Danger of malfunctions
• Check the track rod, especially the ball joint, for deformation and crack formation.
• Alignment and repair of damaged or deformed parts is not permitted.
• If the ball joint sealing bellows are defective, renew the track rod/ball joints.
• Always renew defective and damaged push rod and track rod parts.
• Check the steering gear central position. Any corrections to the steering central position must
always be made at the push rod.
• Ensure that all the axle and steering transmission joints and wheel bearings are free of play.
Note
After exchanging the track rod, the vehicle steering geometry must be remeasured and, if
necessary, adjusted.
Special tools
[154] Ball joint remover 80.99601-6024
• Pressing off the ball joint in conjunction with:

• Hydraulic pump [155]
• Flat hydraulic cylinder [156]
[155] Hydraulic pump 80.99620-6008

• Ball joint remover [154]
• Flat hydraulic cylinder [156]
[156] Flat hydraulic cylinder 80.99644-6000

• Hydraulic pump [155]
• Ball joint remover [154]
• Pulling off the steering arm
• Extracting and filling the kingpin oil in conjunction

with:
• Measuring jug [159]
9 - 182 G5
[159] Measuring jug 80.99629-0030
• Filling the kingpin oil in conjunction with:

• Universal hand pump [158]
[160] Open-ended spanner, size 34 80.99603-0256
• Setting the track
G5 9 - 183
Removing the track rod/steering arm Unscrewing the track rod lock nut
Checking the track rod

Note
Corrosion in the track rod joint can mean
that the axial or horizontal play appears
correct even though it actually isn't.
• Check the ball joints for ease of movement by

turning the track rod
If there is corrosion in the ball joint, renew the track
rod/ball joint.
Checking the axial play
CAUTION
Danger of injury due to uncontrolled
steering of the wheels
• The vehicle must be standing on solid
ground
• Unscrew the lock nut (2) for the ball joint (1)
• Repeat the same procedure for the other ball joint
Pressing off the track rod joint
• Push the ball joint (1) up and down using an

assembly lever
• No play must be measurable in the adjusting
thread (2) of the track rod (3)
The maximum permitted axial play in the ball joint
(1) is max. 2 mm
Checking the horizontal play

• Turn the steering wheel back and forth to check
the horizontal play on the track rod
The maximum permitted horizontal play on the track
rod is max. 2 mm
• Mount the Flat hydraulic cylinder [156] (4) on the
Ball joint remover [154] (3)
• Connect the Hydraulic pump [155] to the Flat
hydraulic cylinder [156] (4)
• Insert the Ball joint remover [154] (3) between the
ball joint and the steering knuckle arm
• Attach the track rod (2) to the steering arm using
chain
• Secure the Ball joint remover [154] (3) using chain
(1) to prevent it falling down
• Press the ball joint off the track rod (2)
9 - 184 G5
Removing the track rod Removing the steering arm
• Remove the track rod (1) from the steering knuckle

Note
arm (2)
Note the different lengths of the external
Removing the ball joint hexagonal round screws and mark their
installation positions.
• Unscrew the external hexagonal round screws (1)

and (2) for the steering arm (3) from the steering
knuckle
Pulling off the steering arm
Note
The visible thread length of the ball joint
(1) must be exactly as long as the visible
thread length of the adjusting sleeve.
• Undo the clamp mounting bolt (3)

• Unscrew the ball joint (1) from the adjusting sleeve
(2)
• Unscrew the adjusting sleeve (2) from the track
rod (4) using the Open-ended spanner, size 34
[160]
WARNING
Danger of environmental pollution
• Collect the emerging oil in a suitable
container and dispose of in the correct
manner
G5 9 - 185
• Unscrew the screw plug (3) and remove the Installing the track rod/steering arm
sealing ring
• Extract the oil in the kingpin using the Universal Installing the steering arm
hand pump [158]
• Insert the rounded side of the pressure pin (1) into
the oil filler hole in the steering knuckle
• Screw the Removing device [157] (2) into the
kingpin
• Pull off the steering arm (4) by screwing in the
pulling screw
Note
Renew external hexagonal round screws
(1) and (2).
• Apply a light coating of DS1KG high-temperature

paste on the guide of the steering arm (3) (the
contact surface of the steering arm (3) must
remain free of grease)
• Insert the steering arm (3) through the steering
knuckle and into the axle housing
Installing the ball joint
WARNING
Danger of malfunctions
• After setting, the visible thread length of
the ball joint (1) must be exactly as long
as the thread length of the adjusting
sleeve
• Use the Open-ended spanner, size 34 [160] to

screw the adjusting sleeve (2) into the track rod
(4) until the thread of the adjusting sleeve (2) is
fully screwed into the track rod
9 - 186 G5
• Screw the ball joint (1) into the adjusting sleeve (2) Setting the toe-in
until the thread of the ball joint (2) is fully screwed
into the track rod (4)
Installing the track rod
• Undo the clamp mounting bolt (3) for the track rod
(4)
• Set the toe-in by unscrewing the adjusting sleeve
(2) using the Open-ended spanner, size 34 [160]
• Degrease the cone of the ball joint and the steering • Tighten the clamp mounting bolt (3) to 160 - 180
knuckle arm Nm
• Insert the track rod (1) into the steering knuckle
arm (2)
Screwing on the track rod lock nut
• Screw on the lock nut (2) for the ball joint (1)
• Tighten the lock nut (2) to 300 ± 30 Nm
G5 9 - 187
STEERING GEOMETRY
Camber and kingpin inclination
Technical data
Kingpin inclination (A) not adjustable ...............................................................................................5° ± 2´
Camber (B) ....................................................................................................................................1° ± 4´
Note
Explanation of camber and kingpin inclination, see Steering geometry, 1-9.
G5 9 - 189
Toe-in and toe-out on turns
Technical data
Toe-out on turns (A) not adjustable at 20° steering angle on inner wheel ...................18° 30´ on outer wheel
Toe-in VP-09 ................................................................................................................................ 0°-0° 6´
Note
Explanation of toe-in, camber and caster, see Steering geometry, 1-9.
WARNING
Steering geometry cannot be set correctly
• Ensure that the tyre inflation pressure and the tyres are in accordance with MAN-Nutzfahrzeuge
AG specifications
• Ensure that all the axle and steering transmission joints and wheel bearings are free of play
• Check the steering gear central position. Any corrections to the steering central position must
always be made at the push rod
9 - 190 G5
PREPARING TO SET THE STEERING GEOMETRY
Steering geometry
Note
Check the toe-in, camber, caster and toe-out on turns with the vehicle unladen and at the ride
height on turntables.
G5 9 - 191
Preparing to set the steering geometry

• Check the axle transmission components for
damage and wear and repair them as necessary
• Check the steering transmission joints with push
rod for damage and wear and repair them as
necessary, see Removing and installing the track
rod/steering arm, 9-181
• Check the tyres for wear and damage. Renew
damaged or worn tyres
• Check that the tyre inflation pressure at all wheels
is in accordance with the specifications in the
Operator's Manual and correct it as necessary
Steering gear in central position
• Move the front wheels into the straight-ahead

position
• For accurate adjustment, align the mark (1) (slot in
the ball joint shaft) with the mark (2) on the steering
gear
9 - 192 G5

VP09

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Driven Front Axle

Copy deadline 05.2004

Driven Front Axle

We reserve the right to make modifications in the course of further development.

Best wishes from

© 2004 MAN Nutzfahrzeuge AG

Redaktion: VSAID, 2W Technische Informations GmbH, MK, 05.2004

Satz: VSAID, 2W Technische Informations GmbH

Safety regulations .................................................................................................... 1-1

Brake drum ........................................................................................................... 2 - 13

Planetary hub drive

Planetary hub drive .................................................................................................. 3 - 55

Wheel hub ............................................................................................................ 4 - 69

Steering knuckle ..................................................................................................... 5 - 91

Double-joint shaft .................................................................................................. 6 - 109

Drive shaft rotary shaft seal ..................................................................................... 7 - 119

Transverse differential lock

Transverse differential lock ...................................................................................... 8 - 173

Track rod/steering arm

Track rod/steering arm ............................................................................................ 9 - 181

Fitted collar bolt ...................................................................................................................................3 - 63

1. Regulations for preventing accidents leading to injury to personnel

Secure units during their removal.

Working on the brake system

Working on high-pressure lines

Working on the vehicle electrical system

Caution! Battery acid is poisonous and corrosive!

Working on polyamide tubes - danger of damage and fire!

Working whilst the cab is tilted

Working on the air-conditioning system

2. Notes on preventing damage and premature wear on units

3. Limited liability for accessories and parts

Attachments and special bodies

Taking out of operation or putting into storage

4. Handling brake pads and similar components

5. Regulations for avoiding injury and environmental contamination

Cleaning the cooling circuit

Cleaning the filter element

Used engine/gear oil

6. Health protection precautions

- Oils can damage groundwater quality -

Extract from "Information on dealing with used engine oil"

PRESENTATION OF THE UNITS

Axle designation/model plate

(1) Position of model plate on axle drive

Explanation of model plate for VP-09

I= Number of teeth on crown wheel/drive pinion and planetary reduction ratio

Classification Classification terms Explanation

Characteristic data for VP-09

Designation Unit Version

Designation Unit Version

VP-09-06 (for 525/65 R20.5 tyres only)

Designation Unit Version

(1) Steering knuckle arm (6) Planetary hub drive

Reduction ratios/calculations for gear drive

2. Reduction via the planetary hub drive = i-planet (ip).

Example: i-total = 3.00 (ip) x 1.083 (ik) = 3.250

Reduction ratios for the VP-09 axle

i-planet i-bevel drive i-total