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Maintenance and Repair Manual

Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

TABLE OF CONTENTS
1. GENERAL INFORMATION AND MAINTENANCE WORK.
1.1 Introduction
1.2 Ordering spare parts
1.4 Maintenance
1.4.1 Lubricants chart
1.4.2 Service Intervals

2 REPAIR MANUAL
2.1 Replacing complete differential
2.2 Repair to differential
2.2.1 Replacing crown wheel/ pinion
2.2.2 Replacing the differential carrier/differential
2.2.3 Differential lock
2.3 Planet gearbox
2.3.1 Complete replacement of planet gear carrier
2.3.2 Replacing sun gear shaft
2.3.3 Replacing planet gears
2.3.4 Replacing planet bolt
2.3.5 Replacing cogged wheel carrier
2.4.Wheel bearings
2.4.1 Replacing wheel bearing
2.4.2 Adjusting wheel bearing
2.4.3 Replacing Sliding seal
2.4.4 Replacing stub axle (brakes side)
2.5 Replacing half shaft
2.6 Tandem- Bearing
2.6.1 Replacing Transverse joint bearing
2.6.2 Adjusting and checking Transverse joint bearing-play
2.6.3 Replacing shaft seal
2.6.4 Replacing oil seals (No.14 and No.22)
2.6.5 Replacing stub axle
2.7 Cog wheel drive in tandem casing
2.7.1 Replacing bearing (24)
2.7.2 Replacing cog wheel (30) and bearing (28) / (29)
2.7.3 Replacing cog wheels (23)
2.7.4 Replacing cog wheel (6)
2.7.5 Replacing brake line
2.8.Service brake
2.8.1 Disassembling brakes
2.8.2 Checking brake clearance

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Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1. General information and maintenance work.


1.1 Introduction
The production of the FAB 06 will beginning in April 1997. This model contains a
hydraulic differential lock. The four outer planet gearboxes are propelled via the toothed
gears. The axle is not steerable and was constructed to be fitted directly on to a sub-frame
using shear bolts and restrictors. Both tandem casings are fitted using pendulum bearings.
The main drive is obtained via a mechanics 6c drive flange. Two hydraulically operated
louvered brakes suffice as service brakes.

1.2 Ordering spare parts


Replacement parts for this NAF-axle are best ordered direct from an official FABTEK /
USA - stockist , who will usually be able to supply a large range of the required parts from
stock. Even if the parts are not available from stock it is still recommended to order the
parts via your stockist and not directly from the factory as the stockist is usually able to
describe the required parts more accurately and give precise part numbers which in turn
avoids delays due to wrong deliveries or misunderstandings.
Please always quote the full, exact type/ description including factory numbers and year of
manufacture. The location of the identification plate is on the differential housing close to
the oil refill screw (see Fig 1).
Only use NAF original replacement parts. When parts other than original NAF are used
any warranty will cease and the serviceability and service life of the unit may well be
adversely affected.

Fig. 1

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1.3 Working conditions and tools


An orderly repair is achieved if the place of work is adequately illuminated. There should
also be adequate space allowed for laying out of components and group parts.
Furthermore, it is important to have available a complete set of high quality tools. In
addition, also a few special tools are required, which will prove invaluable especially for
repetative repairs. This can save valuable time and aggravation. The special tools are
referred to in their corresponding sections and described or marked with Sk.No.
In addition a certain amount of technical skill is required and for certain repairs, special
schooling.

Maintenance and Repair Manual


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Valid from Factory No.:
Date of Creation:

1.4

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance

1.4.1 Lubricants chart


Location
Differential
Planet gear
Tandem casing
Axle carrier
(Constant level)

Lubricants chart for FAB 06/0


No.
Quantity
40/41/42
10,0 Ltr
50/51
4,0 Ltr ea
60/62/63
46,0 Ltr ea
70/72
2,0 Ltr.ea

Lubricant
SAE 90(Hypoid oil)
SAE 90 / SAE 80
SAE 90 / SAE 80
SAE 90 / SAE 80

Description of lubricant location numbers:


No.: 40 Filling plug for differential oil.
No.: 41 Dipstick for differential.
No.: 42 Magnetised oil drain plug for differential
No.: 50 Magnetised oil drain plug for planet gear.
No.: 51 Magnetised oil filter plug for planet gear.
No.: 60 Oil filler plug/oil control plug for tandem casing.
No.: 62 Oil drain plug for tandem casing.
No.: 63 Magnetised oil dredge plug for tandem casing.
No.: 70 Oil filler plug/oil control plug for axle carrier.
No.: 72 Oil drain plug for axle carrier
(Also see Fig.1)
Examples for type -EP-gear oil SAE 90 specification: API-GL5/MIL-L-2105 B
Fuchs
(Renogear HLS 90)
Texaco/DEA
(M ultigear EP 90)
(Geartex EP-B SAE 85W 90)
M obil
(M obilube HD 90-A)
(M obilube SHC 75 W-90)
Esso
(GX 90)
Shell
(Spirax HD 90) (Spirax M B 90)
BP
(Hypogear 90 EP)
ELF
(Tranself Typ B SAE 80W-90)
Examples for type EP-gear oil SAE 80 specification : API-GL 4 / MIL-L-2105
BP
(Gear Oil EP SAE 80W)
ELF
(Tranself EP SAE 80W)
M obil
(M obilube GX 80-A)
Shell
(HSG 80-90)
Texaco
(Geartex EP SAE 80W)
Please observe notes on lubricant chart for filling quantities

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1.4.2 Service Intervals


NAF-axles are constructed and manufactured as a result of many years of experience and
knowledge of the expectations and requirements of heavy machinery. Smooth and reliable
running of the equipment can however, only be obtained if regular maintenance and care is
given. Adhering to regular service intervals and use of the correct lubricants as per the
lubricants chart are also part of this. Special tools are not required for servicing.

Service interval chart for FAB 06 / 0


Operating hours 0 /
Initiation
Service location (No.)
Differential (40/41/42)
Planetary drive (50/51)
Bogie housing (60/62/63)
Wheel nuts
Louvered service brakes (48)
Various visible nuts and bolts
Tandem bearing/ Axle carrier
(constant level) (70/72)
1 = Initial filling
2 = Oil change
3 = Oil level control
4 = Checking

1
1
1
4

After
1 day

-250

2
2
2
4

250
500
(every) (every)

3
3

2000
(every)
or 1x year
2
2
2

4
4

4
1

(See Chapter 1.4.2.1)


(See Chapter 1.4.2.2)
(See Chapter 1.4.2.3)
(See Chapter 1.4.2.4)

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1.4.2.1 Initial Filling


Caution! The axle is delivered from NAF without oil.
Note: The axle has separate oil chambers for the differential gearbox, axle carrier and
tandem casing. The wheel hub, planet gear and tandem casing share the same oil chamber.
Despite this, oil must be filled or replenished from the various oil filling points as
otherwise, incorrect oil level readings may be obtained due to the fact that the oil ways are
restricted in width.
Differential
Remove oil filler plug (No.40) and fill oil according to the lubricant chart until the upper oil
level mark on the dipstick (No.41) is reached. After about 5 minutes re-check and if
necessary top up. Tightening torque of the Oil filler plug (No.40) is 95+20 Nm. (Fig. 1)
Planet gearbox
Firstly rotate the wheel hub so that the oil drain plugs (No.50) are located vertically facing
downwards in the centre of the axle. Remove oil filler plug (No.51) and fill oil according to
the lubricants chart until it reaches the lower edge of the threaded filler hole. Tightening
torque for oil filler plug (No.51) is 50+10 Nm. (Fig. 1)
Tandem casing
The tandem casings must be positioned horizontally. Remove oil filler plugs (No.60) and
fill with oil according to the lubricants chart until it flows out of the oil control ports
(No.60). Tightening torque of the Oil filler plug (No.60) is 95+20 Nm. (Fig. 1)
Tandem bearings / Axle carrier
The axle must be positioned horizontally. Remove oil filler plug (No.70) and fill oil
according to the lubricant chart until it reaches approx. 10 mm below the lower edge of the
threaded part of the filler port (No.70). Tightening torque for oil filler plug (No.70) is
50+10 Nm.

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1.4.2.2 Oil Change


Note: Remove dirt and grime from area around plug (No.40 /42) and dipstick (No.41) prior
to commencing work.
Differential
Change oil only when oil is warm. Remove oil filler plug (No.40) and then open oil drain
plug (No.42) and drain oil completely. Clean magnet of oil drain plug (No.42) of metal
shavings and residue prior to re-fitting. Refill oil according to lubricants chart until it
reaches the upper marking of the dipstick (No.41). Tightening torque for oil filler plug
(No.40) is 90 + 10 Nm. Tightening torque for oil drain plug (No.42) is 50+10 Nm. (Fig. 1)
Planet gearbox
Change oil whilst it is warm and at the same time as changing the differential oil. To do this,
rotate wheel hub until oil drain plugs (No.50) are at the very base. (Fig. 2). Clean oil filler
plug (No.51) and oil drain plug (No.52) including surrounding area of dirt and debris.
Remove oil drain plugs (No.50) and drain oil completely. Clean the magnet on the oil drain
plug (No.50) of metal shavings and debris before refitting. Then rotate hub 90 degrees in
anti-clockwise direction until the plugs are in a horizontal position (Fig. 3). Fill oil in the
upper opening according to the lubricants chart until the oil level reaches the lower edge of
the horizontal threaded part (No.50). Tightening torque of the plug (No.50/ 51) is 53+5
Nm. (Fig. 3)

Fig. 2
Fig. 3
Tandem casing
Change oil whilst it is warm and at to the same time as changing the planet gearbox oil. The
tandem casings must be horizontal. Clean surrounding area and oil filler plug (No.60), oil
drain plug (No.62) and sump oil drain plug (No.63) of dirt. Before draining the oil the
vehicle must be out of operation for at least 30 minutes to allow the oil dredge to settle in
the oil sump. Firstly, open oil drain plug (No.62) ( 2 plugs per tandem casing) and drain
escaping oil in to a clean container because this part of the oil may be re-used. Then open
sump oil drain plug (No.63) (2 bolts per tandem casing) and drain the rest of the
contaminated oil completely. Clean the magnet of the sump oil drain plug (No.63) of dirt
and metal shavings before inserting and tighten oil drain plug(No.62) oil tight. Fill with oil
according to the lubricant chart until oil flows out of the control opening ( the clean oil
previously saved may be re-used at this stage). Tightening torque for oil filler plug (No.60)
and oil drain plug (No.62/No.63) is 95 + 20Nm. (Fig. 17).

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

1.4.2.3 Checking oil control


Note: Clean surrounding area of oil plug of dirt.
Differential
If necessary top up oil level to the upper control markings on the dip stick (No.41). (Fig.
1)
Tandem casing
Check the oil level on the tandem casings which must be level, Remove oil filler plug (No.
60). The Oil level should be at the lower edge of the filler port (No. 60). If necessary top
up. Tightening torque of the oil filler plug (No. 60) is 95 + 20 Nm. (Fig 1)
Tandem bearings /Axle carrier
The tandem bearing has a constant oil filler and therefore an oil change is not anticipated.
The oil drain plug (No.72) is intended for repair work. The axle must be horizontal. Oil
filler plug (No.70) and its surround must be cleaned from dirt and debris and then remove
plug. The Oil level should be approx. 10 mm under the threaded edge of the filler port
(No.70). If necessary oil may be topped up according to the lubricants chart. Tightening
torque for oil filler plug (No.70) is 50 + 10 Nm. (Fig. 1)

1.4.2.4 Checking
All visible nuts and bolts.
Through strain and vehicle vibrations nuts and bolts can settle. In order to avoid
unnecessary damage or leakages preventative tightening is recommended The glued nut for
the pinion flange fixing (pinion flange lock) must not be re-tightened.
Wheel nuts
Through strain and vehicle vibrations the wheel nuts can settle. Regular tightening will
avoid possible damage to the bearing centralisation on the wheel. Tightening torque for
wheel nuts is 550 Nm.
Louvered service brake
Check louver set and gap and if necessary adjust or replace louvres. After loosening plugs
(No.57) and with slackened brakes measure using feeler gauge the gap ( gap between flange
and inner louver).(Fig. 11)
Air gap:
min: 1.8 mm required
max: 4.0 mm permitted
For adjustment and replacement see repair manual

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2 Repair Manual
2.1 Replacing complete differential
(See Fig. 4)
Note! If a large amount of damage has been caused to the differential it is advantageous to
replace the complete differential rather than repairing it. To do this, it is necessary to
remove the complete axle from the chassis.

Drain oil from differential.


Loosen prop shaft.
Remove axle from the vehicle.
After removing Hex. Bolts (No.5) on both sides of the differential take off or pull out
axle carrier (No.1/2) including side panels.
Note! Original NAF replacement or repair differential parts have been adjusted correctly
by the factory.
Differential parts which were not overhauled by NAF must be checked for their correct
bearings and tooth impression settings before assembly.
Remove rust inhibiting coating on fitting face.
Renew O-Ring (117.716).
Thread-in cog-wheel profile of the half shaft in to sun gears by slightly turning on the
pinion flange.
Then push together axle carrier up to flange position paying attention to the clamping sleeve.
Replace Hex. Bolts (No.5). Tightening torque is 290 +10 Nm
Replace axle in to vehicle. (Connect brakes and prop-shaft).
Refill oil in differential.
Dont forget to bleed the brakes !
Re-tighten axle securing bolt and test drive.

Fig.4

Maintenance and Repair Manual


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2.2

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Repair to differential

2.2.1 Replacing crown wheel/ pinion


(See Fig. 5)
Note!

Crown wheel and pinion (No.1) can only be replaced together as the teeth have been
meshed together. Parts are engraved electronically with the same numbers.
It is advisable when carrying out such repairs to replace all bearings at the same time.
Remove differential . (Chapter 2.1).
Loosen pinion flange lock nut (No.50) to assist in this,warm to approx. 150C.
Brace pinion flange (No.51) using a canter lever.
(The loosening torque can be up to 1000 Nm.)
Loosen cap screw (No.4) and take off flange (No.6) on crown wheel side.
Remove differential carrier(No.11) with crown wheel (No.13).
Pull off pinion flange (No.51) and pull pinion (No.13) inwards.
Remove Oil seal (No.53).
Check, and if necessary, replace roller bearing (No.8 / 24) belonging to diff. carrier and
(No.43/48)belonging to the pinion
Loosen Hex. bolt (No.9) and press out crown wheel (No.13) from differential carrier
(No.11).
Push new crown wheel on to differential carrier (No.11) and at the same time fit both
the cross shaft locking pin (No.12). Use new Hex. bolts (No.9) and tighten in a
criss-cross fashion with a torque wrench. Tightening torque is 290 + 10 Nm.
Determine the thickness of the shim (No.45) (See Chapter 2.2.1.2).
If replacing, then press the chosen shim (No.45) (in to the differential housing (No.42))
and bearing outer race (No.43 and No.48).
Pull on the diff. carrier (No.11) bearing inner races (of No.8 and 24) with retaining ring
(No.23).
Fitting temperature of bearing inner race (No.8 / 24) is max. 80C.
Push bearing inner race (of No.43) with bearing carrier on to pinion (No.13).
Fitting temperature for bearing inner race (No.43) is max. 80C.
Determine thickness of shim (No.44) (See Chapter 2.2.1.1).
Insert and support pinion (No.13) from inside in to housing (No.42).
First place chosen shim (No.44) and then distance washer (No.47) on to the pinion
(No.13).
Press bearing inner race (for No.48) complete with bearing carrier on to pinion (No.13).
Fitting temperature for bearing inner race (No.48) is max.80C.
Fit Oil seal (No.53) using a fitting tool.
Clean pinion (No.13) and pinion flange lock nut (No.50) of dirt, oil and preservative
material.

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Coat with Loctite 639 the complete length of threaded part of pinion (No.13) and nut
(No.50).
Coat contact face of nut (No.50) with anti-chaff and anti grinding paste.(e.g. Wolfracote
SSP from Klber)
Fit pinion flange (No.51) and pinion flange lock nut (No.50) on to pinion (No.13) and
tighten with 800 Nm. The final tightening position must be obtained within 3 to 5
minutes so that the Loctite will maintain its effectiveness.
Check pinion bearing pre-load using a torque wrench (Pre-load: 0.5 - 6 Nm), and if
necessary change shim (No.44). Make a note of measured pinion bearing pre-load
(See Chapter 2.2.1.3).
Secure flange (No.36) and new O-Ring (No.7) using set screws (No.4). In addition,
tighten flange (No.36) using four temporary assembly bolts M 16 x 30.
Screw in nut (No.25) approx. 1 thread and loosen nut (No.3) approx. 2 threads.
Insert differential carrier (No.11) completely and secure flange (No.17) and new O-Ring
(No.18) using set screws (No.19) In addition, tighten flange (No.17) using four
temporary assembly bolts M 16 x 30.
Adjust float and crown wheel bearing (Tolerance 0.15 - 0.25) (See Chapter 2.2.1.4).
Install differential (See Chapter 2.1).

Maintenance and Repair Manual


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Date of Creation:

Fig. 5

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.1.1 Determining thickness of shims (44)


(See Fig 5)
Press new outer bearing race of (No.43) and (No.48) in to diff. housing (No.42) up to
seating.
Press on to pinion (No.13) inner bearing race (of No.43) including bearing carrier.
Fitting temperature for bearing inner race (No.43) is max. 80C.
Choose 2 to 3 shims (No.44) and shim (No.47).
Assemble allowing a total measurement in the region of 27.82 to 29.26 mm.
Note: When using factory chosen combinations use / check first.
Shim thickness: 0.96 to 1.44 (using 0.04 steps.)
shim (No.47): 25.9 +/-0-2 mm
Insert the pinion (No.13) from inside in to the housing
(No.42) and support.
First place chosen shim(s) (No.44) and then the shim (No.47) on to the pinion (No.13)
(See Fig.5).
Press inner bearing race (of No.48) complete with bearing carrier on to pinion (No.13).
Fitting temperature for inner bearing race (No.48) is max.80C.
Coat contact face of nut (No.50) with anti-chaff / anti-grinding paste.(e.g. Wolfracote
SSP from Klber).
Fit pinion flange (No.51) and pinion flange lock nut (No.50) on to pinion (No.13) and
tighten with 800 Nm.
Check pinion bearing pre-load using a torque wrench and if necessary change shim (No.44).
The pinion bearing must have no axial play but should be able to be turned at 0.5 to 6.0
Nm For bearings which have already been used a value of 0 to 5.0 Nm applies.
(Pinion bearing pre-load for new bearings: 0.5 - 6 Nm).
Adjusted bearing pre-loads should be noted to be used for future crown wheel adjustments.
(See Chapter 2.2.1.3).
Once the correct bearing pre-load has been reached secure pinion flange lock nut (No.50)
with Loctite. (See Chapter 2.2.1)

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.1.2 Determining thickness of Shim(45)


Note! The tooth impression is adjusted through the use of the chosen shim(No.45) .

Fig.6
Determining thickness (Se) of the shim (No.45)
Se = L2 - Le - Lr -L1

A shim thickness of between 2.4 and 3.65 mm must be calculated.


The nearest shim thickness must be chosen. With a max. deviation tolerance of washer
thickness to be calculated from the Se calculation to be 0.1 mm.
L2 = Distance between bearing seat (No.43) and centre of the differential.
Le = Actual adjustment measurement
(engraved on the face of the pinion, approx. 60.1 to 60.4 mm).
Lr = Measure and note head height of pinion.
L1 = Measure actual bearing height of new bearing (No.43). The measurement L1 can lie
between 30,2 and 30,4. (Use vernier gauge with jaw length of at least 120 mm length).

Maintenance and Repair Manual


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Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.1.3 Adjusting pinion bearing


Clean pinion (No.13) and pinion nut (No.50) of oil, dirt and preserving materials.
Coat complete threaded parts of pinion (No.13) and nut (No.50) with Loctite 639 .
Coat contact face of nut (No.50) with anti-chaff/anti-grinding paste. (e.g. Wolfracote
SSP from Klber)
Fit nut (No.50) on to pinion (No.13) tightening with 800 Nm whilst canter levering
against pinion flange (No.51). Use a few sharpblows to the side of the housing in the
area of the pinion bearings to align the roller bearings. The final tightening position must
be obtained within 3 to 5 minutes so that the Loctite will maintain its effectiveness.
Check and if necessary adjust pre-load of pinion bearing using a torque wrench.
The pinion bearing must have no axial play but should be able to be turned at 0.5 to 6.0
Nm. For bearings which have already been used, a value of 0 bis 5.0 Nm applies.
Adjusted bearing pre-loads should be noted for future crown wheel bearing adjustments.

2.2.1.4 Adjustment of end float and crown wheel bearing

Secure flange (No.36) and new O-Ring (No.7) using set screws (No.4).
In addition tighten flange (No.36) using four temporary assembly bolts M 16 x 30 .
Loosen bolt (No.1) and remove the 2 locking panels (No.2).
Screw in nut (No.25) approx. 1 thread and loosen nut (No.3) approx. 2 threads.
Insert complete differential carrier (No.11) and secure flange (No.6) and new O-Ring
(No.7) using set screws (No.4).
In addition, secure flange (No.6) using 4 temporary assembly bolts M 16 x 30.
Rotate both nuts (No.25) and (No.3) until a backlash of between 0.15 and 0.25 mm has
been reached.
Once the correct backlash has been reached secure nut (No.3) using locking panel (No. 2)
and Hex. bolt (No.1).
Adjust bearing pre-load of crown wheel bearing (No.8) and (No.24). To do this rotate
nut (No.23) until a bearing pre-load of between 1.0 - 3.0 Nm is reached.
This calculation can be obtained on pinion nut (No.50) by using a torque measuring
apparatus. To do this, use the pinion bearing pre-load value noted in Chapter 2.2.1.3
adding a torque of 0.5 to 1.5 to it.
Once the correct bearing pre-load has been obtained secure nut (No.25) using locking
panel (No. 2) and Hex. bolt (No.1).
Make a note of the bearing torque obtained.

Maintenance and Repair Manual


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Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.1.5 Bearing pre-load


Loosen temporary assembly bolts and set screw (No.4) at flange (No.6) and remove
flange.
Take out diff. carrier (No.11) and coat tooth edges of 2 tooth hollows (= 4 tooth edges)
on the crown wheel (No.13) using Engineer blue and re-insert diff. carrier (No.11) and
flange (No.6) using temporary assembly bolts.
Move the painted gear in mesh with the pinion to obtain a good tooth impression.
Take off flange (No.6) and remove diff. carrier (No.11) with crown wheel and then
observe the tooth impression markings. If a correct shim thickness has been used a tooth
impression according to Fig. 9 should be achieved otherwise choose a new shim (No.45)
(See Chapter 2.2.1.2).

Fig. 7
Fig. 8
If a tooth impression as shown in Fig. 7 or 8 is present a tooth impression as shown in Fig. 9
should be aimed for by adjusting the pinion through varying the thickness of the shims (45). By
rotating the nuts (3) and (25) the crown wheel will also be adjusted according to Fig. 7 or 8.
Note : With any adjustments, always pay
attention to the correct pre-loading of the bearings
(8) and (24) Also, attention must be paid to the
correct tooth play when adjusting nuts (3) and
(25). Always remove Engineer blue from previous
testing .

Fig. 9
Once the crown wheel backlash and bearing pre-load has been adjusted secure both nuts
(No.3) and (No.25) and locking plate (No.2) using nine Hex. bolt (No.1).

Maintenance and Repair Manual


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Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.2 Replacing the differential carrier/differential


(See Fig. 5)
Note: Both halves of the diff.carrier (No.11) can only be exchanged together. Pay attention
to the position markings and identification mark.

Remove differential . (See Chapter 2.1 )


Remove flange (No.6) .
Take out differential carrier (No.11) and crown wheel(No.13 )
Pull off bearing inner race from (No.8 / No.24) and retaining ring(No.23).
Inspect both roller bearings (No.8 / No.24) and replace if required.
Loosen Hex. bolts (No.9) and press crown wheel (No.13) off differential carrier (No.11).
Remove set screws (No.22) and open differential carrier(No.11).
Remove cross shaft (No.16) with planet gear (No.18) and thrust washer (No.19) as one
unit. Inspect parts and replace if required.
Remove sun gears (No.15) with thrust washer(No.14). Inspect parts and replace as
necessary.
Remove circlip (No.20) and take out coupling sleeve (No.21) and fit this to the new diff.
carrier (No.11).
Adjust the differential carrier by selecting s of the thrust washer (No.61).
Thickness selection of s of the thrust washer (No.14) is 1.5 to 2.5 mm.
To do this provisionally fit both halves of the diff. carrier including all the selected parts
together using 4 uncoated temporary assembly bolts M 12 x 80.
With the aid of a profiled shaft stump rotate the differential. No noticeable resistance or
jerking should be present. The axial play on the sun gear (No.15) must be less than 0.2 mm.
If adjustment is incorrect change thrust washer accordingly and repeat test procedure.
When adjustments are correct then remove the four uncoated temporary assembly bolts
and bolt together using 12 new coated set screws (No.22).
Tightening torque for set screw (No.22) is 115 + 10 Nm.
Press on both roller bearings (No.8 / No.24) and if renewed also replace bearing carriers in
flange (No.6/36). Pay attention to the retaining ring (No.23) on the roller bearing (No.24).
Insert differential (No.11) and flange (No.6).
For test purposes secure both flange sides with 4 temporary assembly bolts M 16 x 30.
Adjust end float and crown wheel bearing (See Chapter 2.2.1.4).
Check tooth impressions. (See Chapter 2.2.1.5).
Remove temporary assembly bolts M 16 x 30.
Install differential (See Chapter 2.1).

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.2.3 Differential lock


Note: Before opening the axle it is imperative to check whether or not the damage is on the
lock itself or on the peripherals.
Checking the functionability of the diff. lock:
Raise vehicle on to axle stands so that wheels are clear of the ground.
Close operating brake or block crankshaft flange and rotate one wheel.
With an open diff.-lock (without pressure in the supply line) the wheels on the
opposite side must rotate in the reverse direction to which they are being turned.
With the diff. lock activated neither the right nor the left wheels should be able to turn.
A small backlash (due to tooth tolerance) is acceptable.

2.2.3.1 Adjusting axial play of the Selector fork


Note: In order to determine the length of the spacer ring sets l the axle must be removed
from the vehicle and the axle carrier disassembled on the diff.lock side.
The axial play of the selector fork must be re-adjusted if the following parts were
replaced: Diff. housing (No.42)
Diff. carrier(No.11)
Selector fork (No.27)
Crown wheel bearing(No.8) & (No.24)
Crown wheel /Pinion (No.13)
Flange (No.6) and (No.36)
Coupling sleeve (No.21)
Sliding sleeve (No.56)
Press selector fork (No.27) home to flange (No.36) without coupling sleeve (No.56),
pressure spring (No.29) or washer set (No.28).
Measure distance X.
Theoretical distance X = 18 mm.
Push selector fork (No.27) including fitted coupling sleeve (No.56) in the direction of
the differential centre until the sliding sleeve cog touches the base of the tooth of the
coupling sleeve (No.21) and measure distance Y.
Theoretical distance Y 16 mm.
s Establishing the thickness of the washer set (No.28).
s min = X measured - Y measured + 0.2 mm
s max = X measured - Y measured + 0.7 mm
Theoretical washer thickness s = 1.5 - 4.0 mm.

Maintenance and Repair Manual


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Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Fig 10

2.2.3.2 Changing valve seal


(See Fig. 5)

Detach supply pipe from diff. lock connector.


Loosen set screw (No.4) and take off flange (No.36).
Loosen Hex. bolt (No.57) and pull off gear lever (No.35).
Press piston (No.37) from the cylinder (No.34).
Disassemble valve seal (No.32) using suitable tool and replace with new one.
Take care when re-assembling that the position of the valve seal (No.32) in the piston
(No.37) is correct.
Replace piston (No.37) back in to cylinder (No.34) using a suitable tool.
Clean thread of selector bar (No.26) and nut (No.57) of dirt, oil and glue residue.
Coat complete threaded area of selector bar (No.26) and nut (No.57) with Loctite 639.
Fit new sealing ring (No.19) and tighten cylinder (No.16) with 300 Nm.

Maintenance and Repair Manual


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Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.3 Planet gearbox


Note: It is not necessary to remove the axle from the vehicle whilst working on the planet
gearbox. It is sufficient to raise the side of the axle which will be worked on and, after
loosening the wheel flange nut, remove the wheel.

Fig. 11

Maintenance and Repair Manual


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Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.3.1 Complete replacement of planet gear carrier


(See Fig. 11)

Raise and secure vehicle .


Remove wheel.
Drain oil (Chapter 1.4.2.3).
Loosen Hex. bolt (No.32).
Pull complete planet gear carrier (No.13) off.
Renew O-Ring (No.35) and place in the recess of the wheel hub (No.34).
Fit complete new planet gear carrier (No.13).
To do this the toothing of the sun gear shaft (No.40) and the 4 planet gears (No.10)
must be brought to a position where meshing can take place. Whilst lightly turning, the
planet gear carrier can now be slid on until the planet gears settle in the cogged wheel
(No.1). Next push the planet gear carrier (No.13) all the way home.
Fit Hex. bolt (No.32). Tightening torque is 115 Nm .
Adjust threaded pressure cap. (See Chapter 2.3.2.1)
Note: Threaded pressure cap = plug (No.16)
Re-fill oil (Chapter 1.4.2.3 -planet gearbox).
Fit wheel.
Lower vehicle .

2.3.2 Replacing sun gear shaft


(See Fig 11)
Remove planet gear carrier (No.13) (See Chapter 2.3.1).
Pull sun gear shaft No.40) from the stub axle (No.27).
Before fitting a new sun gear shaft it is imperative to check the location of the retaining
ring in the cog wheel. Should the retaining ring have fallen over it is best to retrieve this
with a magnet or grabber.
Stick the retaining ring to the face of the sun gear shaft using some grease.
Fit a new sun gear shaft (No.40). Light movement back and forth of the sun gear shaft
will ease the feeding through of the lug profile of the inner louver (No.57).
When replacing the sun gear shaft (No.40) check the setting of the threaded pressure cap
(No.16) and adjust if necessary to avoid axial pressure. (See Chapter 2.3.2.1)
Re-fit planet gear carrier (No.13). (See Chapter 2.3.1)
Refill oil (Chapter 1.4.2.3 -planet gearbox).

Maintenance and Repair Manual


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Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.3.2.1 Checking and adjustment of threaded pressure cap.


Note: Threaded pressure cap = plug (No.16)
(See Fig 11)
In order to achieve this, measure distance (l4) from the wheel hub face (No.34) to plane
face of the sun gear shaft (No.40) and measure distance (l5) from flange face of the planet
gear carrier (No.13) to the contact area of the threaded pressure cap (No.20) with a
depth gauge.
Axial play l5 - l4 must be a minimum of 0.5mm. (Max. allowed. 2.0 mm)
If the measured axial play lies outside these values then the threaded pressure cap
(No.16) should be adjusted using a suitable new washer set (No.19).
To do this the threaded pressure cap (No.16) has to be completely unscrewed.
To ease removal heat to approx. 80C.
Then fit the planet gear carrier (No.13) to the wheel hub (No.34) in accordance with
Chapter 2.3.1 . Lightly tap the sun gear shaft home through the threaded port M 30 x
1.5 using a punch of approx. 20 mm diameter.
Choice of washer set S (No.19)
S min = 22 - A measured
S max = 23 - A measured
A = Distance measured between the recess of the planet gear carrier to the planed
face of the sun gear shaft.
Clean the threaded part M 30 x 1.5 of the planet gear carrier (No.13) of dirt, oil and
preservative material.
Fit threaded pressure cap (No.16) with chosen washer set S (No.19) in to planet
gear carrier and tighten with between 200 and 240 Nm.
Refill oil (Chapter 1.4.2.3 -planet gearbox).

Maintenance and Repair Manual


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Valid from Factory No.:
Date of Creation:

Fig. 12

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.3.3 Replacing planet gears


(See Fig. 11)

Remove planet gear carrier (No.13) See Chapter 2.3.1 .


Put planet gear carrier (No.13) aside with opening facing upwards.
Loosen 4 Hex. bolts (No.2) .
Pull off equally planet gear carrier inner part (No.4) using extractor disk Sk. 2.90-109.
Remove thrust washer (No.6) and pull off planet gears (No.10)
Caution: The cylindrical rollers (No.8) belonging to the needle bearing will now fall
out. Carefully collect all rollers (63 per planet gear ) and inspect them.
If any of the rollers are damaged or have been lost then replace all rollers of the set with
new ones taking care that only rollers of equal diameter are used
(e.g. M 0, M 2 to 4, or M 4 to 6).
Now place cylindrical rollers (No.8) in to the new planet gear (No.10) using grease (each
row contains 21 pieces) place a retaining ring (No.9) between each row. (2 pieces per
planet gear).
Insert temporary shaft 34.2 diameter x 60 long in to planet gear and slide thrust
washer(No.6) over it.
Insert thrust washer (No.11) with its lug facing in the direction of the seating inside the
planet gear carrier (No.13).
Place temporary shaft on to planet bolt (No.7) and carefully push planet gear (No.10)
including bearings on to planet bolt (No.7).
Insert shear sleeve (No.5) or as the case may be, check the quantity.
Align thrust washer (No.6) with lug facing in the direction of the seating on the inside of
the planet gear carrier inner part (No.4).
Press planet gear carrier (No.4) on and with new coated bolts (No.2) screw down.
Tightening torque is 120 + 7 Nm.
Check free movement of the planet gears (No.10) and axial play (min. 0.3 mm) .
Mount planet gear carrier (No.13) complete. (See Chapter 2.3.1).

Maintenance and Repair Manual


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Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.3.4 Replacing planet bolt


(See Fig. 11)

Remove planet gear carrier (No.13) (Chapter 2.3.1) .


Remove planet gears (No.10) See Chapter 2.3.3 .
Inspect and if necessary replace parts .
Tighten extraction plate Sk 2.90-109 using 4 temporary assembly bolts M 12 x 35 and
attaching these to the 4 planet bolts (No.7). Then using the central bolt extract planet
bolt (No.7).
Press in new planet bolt (No.7) using new tolerance ring (No.12).
Insert thrust washer (No.11) with lug facing toward seating inside planet gear carrier
(No.13).
Re-mount planet gears (No.10) See Chapter 2.4.3.
Re-install complete planet gear carrier (No.13) See Chapter 2.4.1.

2.3.5 Replacing cogged wheel carrier


(See Fig. 11)

Remove planet gear carrier (No.13).(Chapter 2.4.1).


Take out circlip (No.37).
Renew cogged wheel (No.1).
Remount circlip (No.37).
Note: The cogged wheel should now be able to be moved radially +/- 0.4 mm on the
cogged wheel carrier (No.30).
Reassemble planet gear carrier (No.13) (Chapter 2.4.1).

Maintenance and Repair Manual


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Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.4.Wheel bearings
(See Fig. 11)

2.4.1 Replacing wheel bearing


Completely remove planet gear carrier (No.13) (Chapter 2 4.1).
Disassemble sun gear shaft (No.40) (Chapter 2 4.2).
Unscrew groove nut(No.39).
To do this, warm groove nut M 85 x 2 (No.39) to approx. 150C (e.g. using a welding
torch) and loosen with a special socket. The loosening torque can be up to 2000 Nm
Take off cogged wheel carrier (No.38) including cogged wheel (No.1).
Pull off equally wheel hub (No.34) and outer wheel bearing (No.36) from stub axle
(No.27) using a suitable puller.
Remove sliding seal (No.29) from wheel hub (No.34) and stub axle (No.27) and wheel
hub (No.34), check and if necessary renew.
Press bearing outer race from the wheel bearing (No.31 and No.36) out from wheel hub.
Push out bearing inner race (No.31) from stub axle (No.27) using a puller and press the
new bearing inner race (No.31) on to the stub axle (No.27).
Fitting temperature for bearing inner race (No.31) is max. 80C.
Insert new bearing outer race (No.31 and. No.36) in to wheelhub (No.34).
Press new sliding seal (No.29) in to wheel hub (No.34) and in stub axle (No.27) using a
suitable assembly tool.
Clean the threaded part M 85 x 2 of stub axle (No.27) and nut (No.39) of dirt, oil, glue
reside and preservatives.
Fully mount wheel hub centrally and pre-warmed bearing inner race of (No.36) on to
stub axle (No.27). If required, use fitting sleeve.
Coat face of cogged wheel carrier (No.23) with Klber-Paste Wolfracote SSP .
Slide on cogged wheel carrier (No.23) with cogged wheel (No.1).
Adjust wheel bearing (See Chapter 2.4.2) and tighten groove nut (No.39) using a special
socket.
Insert sun gear shaft (No.40). Turn the sun gear shaft lightly to and fro in order to ease
the meshing of the inner louvres (No.57) /cog wheel.
(See Chapter 2.3.2)
Re-assemble planet gear carrier (No.13) (See Chapter 2.4.1).

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.4.2 Adjusting wheel bearing

Measure X1 on stub axle (No.27). (Theoretical = 22 +/-0.22. )


X1 = Distance between planed face on stub axle (No.27) and contact face of shims.
Coat face of cogged wheel carrier (No.30) with Klber-Paste Wolfracote SSP.
Tighten nut (No.39) until a bearing pre-load of between 45 to 50 Nm (including oil seal)
on the wheel bearing has been reached. Adjust bearing carrier and wheel bearing by
rotating wheel hub once or twice in both directions and at the same time applying sharp
blows to the outside of wheel hub (No.1) and cogged wheel carrier (No.30) using a
protected mallet.
Measure X2 . (Theoretical X2 = 20 +/- 0.75 )
X2 = Distance between planed face on stub axle (No.6) and planed face on cogged
wheel carrier (No.38).
Select thickness d of shims
max = X1 - X2
min = (X1 - X2) - 0.15
Loosen and remove nut again (No.39).
Clean threaded part M 85 x 2 of stub axle (No.27) and groove nut (No.39) of oil, dirt,
preservatives and glue residue.
Coat planed face of cogged wheel carrier again with Klber-Paste Wolfracote SSP.
(Do not coat groove nut No.39).
Coat complete length of threaded part M 85 x 2 of stub axle (No.27) and groove nut
(No.39) using Loctite 639 .
Fit and tighten groove nut (No.32) using 2000 Nm. When using a torque wrench
amplifier Sk 3.91-1007 with a ratio 5:1 using 400 Nm.
The final setting of stub axle nut (No.39) must be reached within 2 -5 minutes in order
for the Loctite to maintain its full effectiveness.

Maintenance and Repair Manual


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Date of Creation:

Fig.13

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.4.3 Replacing Sliding seal


Refer to Chapter 2.5.1 and 2.5.2

2.4.4 Replacing stub axle (brakes side)


(See Fig. 11)

Disassemble according to Chapter 2.4.1.


Loosen Hex. bolt (No.67) and remove cover plate (No.65).
After loosening hollowed bolt (No.64) remove brake line (No.61).
After loosening Hex. bolt (No.28) and set screw (No.68) remove complete stub axle
(No.27) including louver carrier (No.53).
Take out louver set (No.56 a), (No.56 b) and (No.57).
Loosen counter sunk screw (No.54) and remove louver carrier (No.53).
Loosen set screw (No.20) take out piston (No.52) with coil spring (No.51) and washer
(No.22).
Press out cylinder (No.59) using 2 temporary assembly bolts
M10 (50 to 100
mm long.) Take care not to damage the sealing face.
Remove the shaft seal (No.50) from the stub axle (No.27).
Pull stub axle ring (No.30) off.
Renew O-Ring (No.58) on cylinder (No.59).
Press cylinder (No.59) in to the new stub axle (No.27).
Coat new shaft seal (No.50) in oil and press equally in to recess.
Pre-assemble piston (No.52) with spring (No.51) and washer (No.22) and insert in to
the new stub axle (No.27).
Tighten using new set screw (No.20) to a tightening torque of 34 Nm .
Insert new O-Ring (No.26) on the stub axle (No.27) and secure louver carrier (No.44) in
its correct position on the stub axle (No.27) using counter sunk screws (No. 54).
Tightening torque is 23 Nm.
Push sun gear shaft (No.40) in to stub axle (No.27).
The louver set consists of 8 louvers. 1 outer louver(No.56 a) and 7 inner louvers
(No.57). Insert and mesh the correct layers of inner louvers in to the louver carrier
(No.53) and sun gear shaft (No.40).
Press home using approx. 500 to 1000 N and establish measurement L1.
Actual measurement L1 = 52,2 to 52,7 mm.
In order to achieve L1 it requires replacing outer louvers (No.56 a) with a thickness of s =
2.3 mm against outer louvers (No.56 b) with a thickness s = 2.8 mm.
To do this it may require using anything from 0 to 6 louvers (No.56 b) instead of
(No.56a).
Insert new O-Ring (No.26) and assemble complete pre-assembled stub axle (No.27) on
to connecting flange (No.44).

Maintenance and Repair Manual


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FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Secure using Hex. bolt (No.28) and set screw (No.68).


Tightening torque is 290 Nm.
Connect brake line (No.62) using hollowed bolt (No.64) and new copper washers
(No.63). Tightening torque is 12 Nm.
Secure cover plate (No.65 )to the connecting flange (No.44) using Hex. bolt (No.67).
Tightening torque is 290 Nm.
Bleed brakes at the plug (No.60).
Check clearance. See Chapter 2.7.2.
Replace wheel.
For further assembly see Chapter 2.4.1

2.5 Replacing half shaft


(See Fig. 14)

Reduce oil level in tandem casing by approx. 80 mm.


Loosen and remove Hex. bolt M10 (No.26) on the cover (No.25).
Pull out half shaft (No.1) complete with attached cog wheel (No.19).
Remove circlip (No.23) and pull cog wheel (No.19) complete with both roller bearing
(No.6) out from half shaft (No.1). Check the condition of roller bearing (No.6) and cog
wheel (No.19) replacing parts if necessary.
Slide the cog wheel (No.19) and both roller bearings (No.6) on to new half shaft using
new O-Ring (No.20), retaining ring (No.22) and circlip (No.23).
Slide the assembly including the new half shaft (No.1) in and mesh in to the differential
carrier. Take care that the sealing lip of the oil seal inside the stub axle is not damaged
during this operation. In order to ease the insertion of the half shaft in to the grooved
part of half shaft it should be rotated slightly to and fro.
Re-mount cover (No.25) and tighten down using new Hex. bolt (No.26) and tightening
torque of 67 Nm.
With new bearings adjust bearing pre-load. See Chapter 2.7.4.1.

Maintenance and Repair Manual


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Date of Creation:

Fig. 14

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.6 Tandem- Bearing


Caution!
The tandem see-saw unit is maintenance free and mounted on a transverse bearing which is
submerged in an oil bath. For trouble free operation it is imperative that an adequate oil
level and correct bearing pre-load is maintained.
Therefore , when assembling and disassembling pay close attention so that the seating of
the oil ring on the stub axle (No.17)for the rod seal (No.9) is not damaged.

2.6.1 Replacing Transverse joint bearing


(See Fig. 15)

Remove cover and half shaft. See Chapter 2. 5


Loosen Hex. bolt M16 (No.5) and remove complete side assembly.
Loosen Hex. bolt (No.23) and remove cover (No.24) complete with shim (No.25).
Mount a suitable puller on the flange of the axle carrier (No.1 or No.2) placing it in such
a way that the spindle presses on the planed face of the stub axle (No.17).
Pull off centrally inner race of the transverse joint bearing (No.26) including axle carrier
(No.1 or No.2) Take care not to damage the machined oil seal surface.
Pull off inner race of transverse bearing (No.13) from stub axle (No.17).
Take care not to damage the machined oil seal surface.
Take ring (No.15) and oil seal (No.14) out of axle carrier.
Pull both outer races of transverse joint bearing (Nos.13 & 26) from axle carrier (Nos.1 or
2).
Press new outer race of transverse bearing (No.13 and No.26) in to axle carrier (No.1/No.2).
Fit new oil seal(No.14) and new ring (No.15) in to axle carrier and fill 50% of the hollow
with grease.
Pre-heat new race of (No.13) evenly to max. 80C .Insert new O-Ring (No.12) and push
inner race home until a tight fitting against the stub axle planed face is achieved.
Place axle carrier (No.1 or No.2) centrally on stub axle (No.17).
Pre-heat new inner race of (No.26) evenly to max. 80C and push on stub axle (No.17)
so far until both transverse joint bearings have no more axial play.
Select shim (No.25). See Chapter 2.6. 2
Axial play is 0.05 to 0.2.
Press new seal (No.22) in to the axle carrier (No.1 or No.2).
Place new O-Ring 265 x 4 am on to the flange of the differential.
Secure complete side assembly of the differential using Hex. bolt (No.5).
Tightening torque is 290 Nm.
Place on new gasket (No.24 / Fig. 14).
Secure cover (No.25) using new Hex. bolt (No.26 / Fig. 14) .
Tightening torque is 67 Nm.

Maintenance and Repair Manual


Type:
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Valid from Factory No.:
Date of Creation:

Fig. 15

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.6.2 Adjusting and checking Transverse joint bearing-play


Note: This is to be carried out when side assembly is detached.
Both side assemblies (No.13 & 26) should be adjusted to an axial play of 0.05 to 0.2mm.
Determine A using a depth gauge
Select set of shims (No.25) from 0.1 to 0.2 thicker than measurement A.
Mount shim set (No.25) and tighten cover in a criss-cross fashion using 9 Hex. bolts
(No.23). Tightening torque is 400 Nm.
Push the inner race (No.26) on the flange of the axle carrier (No. 1 or 2) to a tight fit on
the cover (No.24) using light taps.
Place a gauge on the flange of the axle carrier and measure the axial play against cover
(No.24).
Press new seal (No.22) in to the axle carrier.

2.6.3 Replacing shaft seal


(See Fig. 15 and 16)

Firstly disassemble complete side assembly and axle carrier. See Chapter 2.6.1.
Note! When changing the shaft seal the spacer (No.10) can remain in the axle carrier.
Remove the shaft seal (No.9) from the spacer (No.10) using a suitable tool.
Clean assemble grooves of the spacer (No.10) reshape new shaft seal (No.9) in to a
kidney shape and place in the assembly grooves paying attention to the positioning of
the shaft seal (No.9). (Fig 15)
Reassemble complete side assembly and axle carrier. See Chapter 2.6.1 and 2.6.2.

Fig. 16

2.6.4 Replacing oil seals (No.14 and No.22)


See Chapter 2.6.1 / Fig. 15

Maintenance and Repair Manual


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FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.6.5 Replacing stub axle


(See Fig. 15/17/18)

Firstly disassemble complete side assembly and axle carrier. See Chapter 2.6.1.
Loosen hollowed bolt (No.2 / Fig. 14) of brake line.
Loosen Hex. bolt (No.16 and No.21) and remove stub axle (No.17).
Pull out bearing outer race (No.6 / Fig. 14) and check bearing .
Place new oil seal (No.19) in to new stub axle (No.17).
Press bearing outer race (No.6 / Fig. 14) in to new stub axle (No.17).
Place new O-Ring (No.18) on to stub axle (No.17) .
Clean threaded part M 20 in tandem casing of dirt, oil and glue residue.
Assemble stub axle (No.17) positioning it to the correct angle
to tandem casing.
(The brake pipe connector must face 27 upwards in the direction of the brakes side.)
(Fig. 17)
Insert and for the time being tighten down crosswise as shown in Fig. 18 new Hex. bolts
(No.16 and No.21) using Loctite on the thread with a tightening torque of 100 - 150 Nm.
In stage two, again following Fig.18, tighten down cross-wise to a tightening torque of
550 + 30 Nm.
Caution: This operation must be completed within a maximum of 15 minutes. Thus a
max. 15 minutes may elapse from inserting the first bolt to the final torque setting.
This time must not be exceeded as after that neither the bolt pre-load or the Loctite
effectiveness can guarantee an effective seal.
Whilst carrying out this work the stub axle should be well covered so that the gasket
seat will not be damaged. The planed face oil seal tolerance was set to RA <= 0.4 m
and must not exceed Rt = 3.0 m at any point.
Reassemble axle carrier and complete side assembly. See Chapter 2.6.1 and 2.6.2.

Fig. 17

Fig. 18

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.7 Cog wheel drive in tandem casing


Note: It is not necessary to remove axle from the vehicle to work on the cog wheel drive. It
is sufficient when the wheel side which is being worked on is raised on axle stands and
the wheel and tyre assembly are removed.

Fig. 19

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.7.1 Replacing bearing (24)

Loosen Hex. bolt (No.22) and remove cover (No.21) including gasket (No.20).
Insert extractor tool in to the centre of bolt M 12( No.18) and extract bolt No.18.
Renew needle bearing (No.24) and O-Ring (No.19) on bolt (No.18).
Insert bolt in the opening of the tandem axle carrier (No.31), cog wheel (No.23) and
spacer (No.16). Turn bolt (18) in to the correct position so that clamping sleeve (No.17)
will come to rest in the groove of the bolt(No.18).
Insert new gasket (No.20) and place cover (No.21) in the groove of bolt (No.18).
Tighten new Hex. bolts with Loctite in to threaded part (No.22).
Tightening torque is 46 Nm.

2.7.2 Replacing cog wheel (30) and bearing (28) / (29)


See Fig. 19
Loosen Hex. bolt (No.67) and remove cover plate (No.65) .
Loosen hollowed bolt (No.64)
Loosen Hex. bolt (No.47) and remove complete planet gearbox including connecting
flange (No.44).
Remove cog wheel (No.30) with both bearings (No.28 / 29) from the tandem axle carrier
(No.31).
Press new bearing (No.28 / 29) on to the new cog wheel (No.30) .
Place circlip (No.33) in to groove and glue retaining ring (No.32) in cog wheel (No.16)
using grease.
Place pre-assembled cog wheel (No.30) in to tandem axle carrier (No.31) insert new
O-Ring (No.42) and assemble complete planet gearbox including connecting flange
(No.44) on to tandem axle carrier (No.31) and tighten down with Hex. bolts (No.47).
Connect brake line (No.61) to threaded part using hollowed bolt (No.64) and two new
copper washers (No.63).
Secure cover plate (No.65) using Hex. bolts (No.47). Tightening torque is 290 Nm.
Check threaded pressure cap setting and reset if necessary.
See Chapter 2.3.2.1

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.7.3 Replacing cog wheels (23)


See Fig. 19

Loosen Hex. bolts (No.67) and remove cover plate (No.65).


Loosen hollowed bolt (No.64).
Loosen Hex. bolt (No.47) and remove complete planet gearbox with connecting flange (No.44)
Remove cog wheel (No.30) including both bearings (No.28 / 29) from tandem axle carrier
(No.31)
Depending on which of the cog wheels (No.23) is being removed remove either the outer
bolts (No.18) or all 3 bolts from one wheel side. See Chapter 2.7.2
It is now possible to remove the cog wheels (No.23) through the large opening
(296 diameter )
The spacer (16) can be passed out through the corresponding opening (71 diameter)
Attention must be paid when pressing in spacer (No.16) so that the hardened planed
face and the bevel on the inner diameter of each spacer points to the outside of the
opening (71 diameter)
Place new cog wheels (No.23) in to tandem casing through the large opening
(296 diameter) and starting with the inner wheel assembled as per 2.7.1
Place pre-assembled cog wheel (No.30) in to tandem axle carrier (No.31). Insert new
O-Ring (No.42) and assemble complete planet gearbox including connecting flange
(No.44) on the tandem axle carrier (No.31) and tighten down with Hex. bolt (No.47).
Connect brake line (No.61) using hollowed bolt (No.64) and 2 new copper washers
(No.63) on to bolts.
Secure cover plate (No.65) using Hex. bolt (No.47).
Check threaded pressure cap and re-adjust if necessary See Chapter 2.3.2.1

2.7.4 Replacing cog wheel (6)

Reduce oil level in tandem casing by approx. 80 mm.


Loosen Hex. bolt (No.10) and remove cover (No.8) with gasket (No.9).
Pull out cog wheel (No.6) with half shaft( No.11 ).
Press out bearing outer race (No.2) and oil seal (1) from stub axle (No.45) and bearing
outer race of (No.7) from cover (No.8)
Pull off bearing inner race (No.2) and (No.7) from cog wheel (No.6)
Press in new oil seal (No.1) and new bearing outer race (No.2) in to stub axle (No.45).
Press in new bearing outer race (No.7) in to cover (No.8) and press on new inner race
(No.2) and (No.7) on to new cog wheel (No.6)
Slide new cog wheel (No.6) with new O-Ring (No.13), retaining ring (No.14) and circlip
(No.15) on to half shaft (No.11) and insert assembly centrally. At the same time the
inner half shaft profile is to be inserted in to the lug of the differential, in other words
the diff. lock sliding sleeve

2.7.4.1 Adjusting bearing play

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Place on cover (No.8),for the time being without gasket (No.9), securing this using 4
Hex. bolts (No.10), press with equal pressure against bearing (No.7) Tightening torque
for Hex. bolts is 2 to 3 Nm.
Measure gap s between cover(No.8) and flange face of tandem axle carriers (No.31) at
4 places (Measurements s1 / s2 / s3 / s4 ) and calculate the average measurement:
Average measurement s
s= (s1 + s2 + s3 + s4 ) : 4 =
mm
Select a gasket thickness or gasket set 0 bis 0.2 mm thicker than calculated s
Gaskets (No.9) are available in thicknesses of 0.5 mm and 0.7 mm.
Fit chosen gasket set (No.9) and secure cover (No.8) using new Hex. bolts (No.10).
Tightening torque is 67 Nm.
Note! The bearings (No.2) and (No.7) have now been adjusted depending on fitting
tolerances with an axial play of 0.25 mm and a bearing pre-load of 3 Nm

2.7.5 Replacing brake line


To disassemble brake line (No.5) firstly remove outer cog wheel (No.30) as per Chapter
2.7.2 and middle cog wheel (No.6) as per Chapter 2.7.4.
Loosen both hollowed bolts (No.3) and (No.38) and remove brake line (No.5).
Insert new brake line (No.5) and secure using hollowed bolts (No.3) and (No.38) as well
as new copper-washers (No.4) and (No.39). Secure hollowed bolts using Loctite type
222 tightening to 20 Nm
Further assembly as per Chapter 2.7.2 and 2.7.4.

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

2.8.Service brake
Note: For work on the service brake it is not necessary to remove the axle from the vehicle.
It is sufficient if the axle side which will be worked on is raised and the wheel removed.

2.8.1 Disassembling brakes


(See Fig. 11)
Loosen Hex. bolt (No.67) and remove cover plate (No.65).
After loosening hollowed bolt (No.64) also remove brake line (No.61).
After loosening Hex. bolt (No.28) and set screw (No.68) remove complete planet
gearbox including louver carrier (No.53).
Take out louver set (No.56 a), (No.56 b) and (No.57).
Loosen counter sunk bolt (No.54) and remove louver carrier (No.53).
Loosen set screw (No.20) and remove piston (No.52) with coil spring (No.51) and
washer (No.22).
Using 2 temporary assembly bolts M10 (50 to 100 mm long) push off cylinder (No.59).
Remove shaft seal (No.50) from stub axle (No.27).
Take care whilst doing so not to damage seal face.
Renew O-Ring (No.58) on cylinder (No.59).
Press cylinder (No.59)in to stub axle (No.27)
Coat new shaft seal (No.50) with oil and press equally in to grooved recess.
Pre-assemble piston (No.52) with spring (No.51) and washer (No.22) and insert in to
stub axle (No.27) .
Insert new set screw (No.20) and tighten with 34 Nm .
Insert new O-Ring (No.26) and tightening louver carrier (No.44) in the correct position
on stub axle (No.27) using Hex. bolt (No.54). Tightening torque is 23 Nm.
The louver set consists of 8 louvers 1 outer louver(No.56 a) and 7 inner louvers
(No.57) Place the correct layer of louvers into louver carrier (No.53) and mesh in to sun
gear shaft (No.40).
Press home using approx. 500 to 1000 N and establish measurement L1.
Actual measurement for L1 = 52.2 to 52.7 mm.
By exchanging outer louvers (No.56 a) with a thickness of s = 2.3 mm against outer
louvers (No.56 b) with a thickness of s = 2,8 mm it is possible to set measurement L1.
It may be necessary to use from 0 to 6 louvers (No.56b) instead of louvers (No.56 a).
Fit new O-Ring (No.26) and re-fit complete planet gearbox including connecting flange
(No.44).
Tighten using Hex. bolts (No.28) and set screw (No.68) .
Tightening torque is 290 Nm.
Connect brake line (No.62) using hollowed bolt (No.64) and new copper washer
(No.63). Tightening torque is 12 Nm.
Secure cover plate (No.65) on to connecting flange using Hex. bolt (No.67) (No.44).
Tightening torque is 290 Nm.

Maintenance and Repair Manual


Type:
Description:
Valid from Factory No.:
Date of Creation:

FAB 06 / 0
Tandem Axle TAP 7501.126
01
11.05.1999

Bleed brakes at plug (No.64).


Check clearance See Chapter 2.7.2.
Replace wheel

2.8.2 Checking brake clearance


(See Fig. 11)
Open nipple (No.48) and loosen brake .
Measure gap between contact area and inner louver using a feeler gauge (gap).
The clearance when new is adjusted at 1.8. to 2.5 mm.
Should the clearance exceed 4.0 mm then the louver set must be checked and if necessary
replaced. Alternatively the clearance must be re-adjusted.
Do this by exchanging outer louvers (No.56 a) to (No.56 b) .
See Chapter 2.7.1.
Tighten nipple (No.48) to 95 Nm.

Revision reserved
Neunkirchen on the May 11, 1999