GROUP 30

AXLE ASSEMBLY

DISMANTLING AXLE 172 - 177 - 272 - 277 - 279

30-3-7 EN

25 / 09 / 1998

INDEX

Introduction .............................................................................................

Maintenance and lubrication - Symbols..................................................

Brakes.....................................................................................................

Brakes / External adjustment..................................................................

10

Parking brakes / External adjustment .....................................................

14

Planetary - 4,25 - 5,25 ............................................................................

16

Planetary wheel hub - 4,25 - 5,25...........................................................

17

Epicycloidal reduction - 4,25 - 5,25.........................................................

18

Axle 177 - Epicycloidal reduction - 6,23..................................................

19

Disassembly articulation 272 - 277 - 279................................................

22

Assembly articulation 272 - 277 - 279 ....................................................

23

Assembly articulation 272 - 277 - 279 ....................................................

26

Disassembly steering cylinder 277 - 279 ................................................

27

Steering cylinder assembly 277 - 279.....................................................

29

Bevel pinion support ...............................................................................

31

Axle bevel pinion support 277 - 279 .......................................................

35

Bevel pinion support ...............................................................................

36

Axle bevel pinion support 277 - 279 .......................................................

37

Axle adjustments of bevel gear set 172 - 177 - 272 ...............................

38

Taper roller bearings of differential .........................................................

39

Adjusting bevel gear set 172 without brake ............................................

42

Disassembly of differential......................................................................

44

Assembly of the differential.....................................................................

45

Self locking differential............................................................................

46

Conversion tables ..................................................................................

47

Tightening torques ..................................................................................

47

Trouble shooting .....................................................................................

48

Special tools ...........................................................................................

52

-3-

-4-

INTRODUCTION

The efficienty and continued operation of mechanical units depends on constant and correct maintenance and also
on efficient repair work should there be a break-down or malfunction.
The instructions in this manual have been made based on a complete overhaul of the unit. However the mechanic
must decide whether or not it is necessary to dismantle the individual components when only partial repair work is
needed.
The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the
various phases of the operations, allows accurate work to take place. Therefore all the information needed for
correct disassembly, the relative checks and assembly of each individual component, has been written down.
In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should
be consulted. In describing the following operations it is presumed that the unit has already been removed from the
vehicle.
IMPORTANT : Throughout the phases of repair or maintenance work it is advisable to use proper equipment such
as : trestles, or supporting benches, plastic or copper hammers, appropriate levers, extractors and specific
spanners or wrenches. So that the work is facilitated and the working surfaces and the operators themselves are
protected.
Before going on to disassemble the parts it is best to thoroughly clean the unit, removing any encrusted or
accumulated greases and then drain the oil through the oil-draining plugs.

INTRODUCTORY STATEMENT
All the disassembled mechanical units should be thoroughly cleaned with appropriate products and then restored
or replaced if damage, wear, craking or seizing have occured.
In particular, thoroughly check the state of all moving parts (bearing, gears, crown wheel and pinion, shafts) and
sealing parts, (O-ring, oil shield) which are subject to major stress and wear. In any case it is advisable to replace
the seals every time a component is overhauled or repaired.
During assembly the sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and
pinion, replacement of one reguires the replacement of the other.
During assembly the prescribed pre-loading and backlash of the parts must be maintained.

MAINTENANCE AND REPAIR

We have compiled these instructions for maintenance and repair in order to facilitate any such work on the
CLARK-HURTH Components differential units and gear change units. Drawings necessary in order to carry out
maintenance and repair work can be bought directly from us.
Spare parts can be ordered either through the manufacturer of the vehicle or directly from us.

-5-

-6-

MAINTENANCE AND LUBRICATION - SYMBOLS

PARTS TO BE LUBRICATED

SYMBOLS

SEE OPERATOR'S MANUAL OF LIFT TRUCK.

Removal of subassemblies

FREQUENCY
Fitting of subassemblies

SEE OPERATOR'S MANUAL OF LIFT TRUCK.

Removal of cumbersome parts

Fitting of cumbersome parts

Caution - important notice

Check/adjust
eg.
torques,
measurements, pressure etc.

T = Special tools

P = 38

Fit the right way round

Check, examine, visual inspection

May be re-used (replace if necessary)

Replace on every fitting

Remove - apply safety device

Apply safety device, fix with adhesive

(liquid mastic)

Avoid damage to materials, damage to

parts

Mark before removal (for assembly)

Load/fill (oil, lubricant)

Drain, lubricant

Tighten

Pressurize hydraulic circuit

-7-

BRAKES
WEAR
CHECK
AND
REPLACEMENT OF BRAKE
DISCS :
Use discs till minimum thickness
of S = 4,5mm.
T. 23

Loosen lock nuts and remove the

axle housing horizontally.

Remove brake discs.

NOTE : If the brake discs must
not been replaced,
remove the complete
pack without changing
the position of the discs.

For assembly proceed in reverse

order, align lubrication holes.

Use compressed air to eject the

brake pistons.
This operation should only be
carried out if necessary.

-8-

BRAKES
Disassembly of piston ponts.
bar

ASSEMBLY
Even if the brake pistons have
not been removed, seat them to
the bore botton.

bar

-9-

Check for leakage using 0,51 bar

compressed air for 10 minutes
per side.

BRAKES / EXTERNAL ADJUSTMENT

bar

WEAR CHECK OF BRAKE

DISCS :
Brake the axle and check the
tickness of the disks through the
oil fill hole.
Use discs till minimum thickness
of S = 4,5 mm.

T. 23

REMOVE BRAKE DISCS

Loosen lock nuts and remove the
axle housing horizontally.

Loosen the 3 adjuster screws :

remove the pressure plate.
NOTE : If the brake discs must
not been replaced,
remove the complete
pack without changing
the position of the discs.

Ckeck that the springs are efficient.

Remove the brake plunger.

MOUNTING THE BRAKE

PLUNGERS
Mount the antiextrusion ring on
the outside followed by the o-ring.

- 10 -

BRAKES / EXTERNAL ADJUSTMENT

Tighten the 2 mobile stud bolts,
lubricate the retention zones
before mounting the plungers.

ASSEMBLING THE BRAKE

DISK PACK
Align the oil holes of the
individual disks.

Mount the pressure plate with the

vertical rods. Partially tighten the
3 adjuster screws.

Mount with loctite 242.

M12 8.8 bolt driving torque = 86
Nm on axle with bracket fixing.
M12 10.9 bolt driving torque =
120 Nm on axle with pendulum
fixing.

BRAKE
DISC
P L AY
ADJUSTMENT
Gradually and fully turn (Driving
torque ~ 50 Nm) the 3 adjuster
screws in an anticlockwise
direction, then turn them 3/4 of a
turn in a clockwise direction to
achieve a 0.75 mm play between
the discs. Lastly, lock in place
with the check nut.
- 11 -

BRAKES / EXTERNAL ADJUSTMENT

- 12 -

- 13 -

PARKING BRAKES / EXTERNAL ADJUSTMENT

Mounting the internal lever.
Mount the bush and stop plate
using Loctite 573.
M6 bolt driving torque = 10Nm.
Mount the lever so thet in the
relase position, it forms A 11
angle in the opposite direction to
that of pulling.

Adjusting the parking brake

with mechanical stops
The play between the brake disks
and parking brake levers on
these axles will not need
adjusting during the first
assembly operations (this will
have already been carried out in
the factory).

Adjustment procedure for

maintenance operations
1 Brake disk play adjustment.
2 Free both transmission levers
from the control cable and
from any other restraints.
3 Apply a ~ 8 10 N load to the
levers so that the lever itself
rests on the pressure plate
(without deforming the levers
or internal springs (photo 5).
4 Having set this position, allow
the stop adjuster screws to
touch the levers and lock in
place with the check nut
(photo 5-6).
5 Position the plate (photo 7)
and couple the external spring,
locking it with a 75-77 mm pull
(photo 8).
6 Re-connect the brake control
cables to the levers.
7 Check that during the brake
disengaging phase, the levers
both return to the position in
which they rest on the stop
screws.

- 14 -

- 15 -

PLANETARY - 4,25 - 5,25

DISASSEMBLY THE PLANET
SUPPORT
Remove all 3 pins before
removing the planets from the
central hole of the cover.

ASSEMBLY
Take care to center the thrust
washer.
T. 15

Proceed in reverse order when

mounting the support.
Champfer after having mounted
the circlip as indicated.

- 16 -

PLANETARY WHEEL HUB - 4,25 - 5,25

DISASSEMBLY
Before removing the axle shaft,
lock the brake to keep the disks
in place.

Use the partly tightened original

screws and a plate for the puller.

Remove the bearing and spacer

with a puller if necessary.

T.10

- 17 -

ASSEMBLY
Check the rotation torque,
allowing the taper bearing a slight
end play.
The tangential force must be
20-30 N.

EPYCICLOIDAL REDUCTION - 4,25 - 5,25

ADJUSTMENT
Measure the difference to
establish the required shim size,
EG. 0,9 mm.
Shim pack from 0,88 to 0,92 mm.

Insert the pin and thighten the

bolts to 250 Nm using Loctite
270.

The tangential force must be max

40 50 N.
If corrections are required, add or
remove shims considering that
0,02 mm cause a variation of
~ 10 N.

T.31

- 18 -

AXLE 177 - PLANETARY REDUCTION - 6,23

DISASSEMBLY

ASSEMBLY

Check the reference numbers.

Torque the screws at 315-320 Nm.

- 19 -

AXLE 177 - PLANETARY REDUCTION - 6,23

DISASSEMBLY
T 32

Follow the operations on page 17.

ASSEMBLY

Use arexon adhesive (Liquid

gasket material).
T. 38

ADJUSTMENT
Follow the operation on page 17.

Use loctite 242 on the thread and

grease around the pin diameter
to prevent lock up.

Torque to 220 230 Nm with a

torque wrench + stop threaded
MANITOU : 62079.

- 20 -

- 21 -

DISASSEMBLY ARTICULATION 272 - 277 - 279

Disassembly of steering joint.

Use the threaded holes in the pin

as a puller.

Check the bearing races for

possible damage.

Remove the double cardan joint.

Remove the nut and the stop
screw.

Before removing the double

cardan joint lock the differential
and the brake to ensure that the
disks remain in position.

- 22 -

ASSEMBLY ARTICULATION 272 - 277 - 279

Insert the external bearing race of
the taper roller bearing.
Insert the double cardan joint.
277
T. 21 - 24

272 - 279
T. 08

Tighten the lock nut at 86 Nm

using a torque wrench.

Assembly of a acla ring type 279.

Assembly of ring type 277.

T. 05

- 23 -

ASSEMBLY ARTICULATION 272 - 277 - 279

- 24 -

- 25 -

ASSEMBLY ARTICULATION 272 - 277 - 279

Taper roller bearing preload
calculation.

Check the rotation torque.

Type 279 15-17 Nm.
Type 277 21-23 Nm.

Tighten the screws with a torque

wrench.
Type 279 120-123 Nm.
Type 277 190-193 Nm.

- 26 -

DISASSEMBLY STEERING CYLINDER 277 - 279

Removing the steering cylinder
from the axle.

ASSEMBLY
Carry out the above operations in
reverse order.
Use silicone.

Caulk.

- 27 -

DISASSEMBLY STEERING CYLINDER 277 - 279

HOW TO USE THE CYLINDER SERVICING TOOLS DRWG 279.24.620.01.

45x53x8 piston rod seals ; 45x52,9x1,5 anti-extrusion ring ; 82x4 O-ring, can be mounted without the aid of
tools.
Proceed in the following way to mount the 90x74, 5x6,3 piston seal :
Insert tool n 400437 along the piston rod and allow it to fit on the piston. The 90x74,5x6,3 piston seal
consists of two parts : an O-Ring in nitrile rubber and a retention pad.
Allow the nitrile rubber O-Ring to slide along the tapered part of tool n 400437 until it fits into its housing.
Proceed in the same way with the retention pad. The 30x74x6,3 piston seal will mounted in its housing, but its
original shape will have expanded. It must be recalibrated with tool n 400436 in the following way.
Remove tool n 400437, mount the two 5,5x2,5x270 guide rings in their seats. Mount tool n 400436 on the
piston with the chamfer pointing forwards and leave it mounted on the piston for 10-15 minutes. After this,
assemble the piston rod on the cylinder body in the following way.
After having mounted the 45x52,9x1,5 anti-extrusion ring seals 45x53x8 piston rod seal and 45/53x4,7
scraper, insert tool n 400438 on the end of the piston rod after having spread it with a light film of grease on
the contact area between the piston rod and the tool itself. This will improve the adhesion a between the two
parts.
Insert the piston rod + tool n 400438 n 400436 into the cylinder body. Part n 400436 will be pushed out
immeditely after the piston rod slides in the cylinder.
The piston rod must be mounted so that the piston comes out from part n 400436 on the side opposite the
chamfer.
Now remove assembly cone n 400438 from the piston rod and insert it into the opposite end in the same
way. After having mounted all the seals on to the head, fit this on to the piston rod, allow it to slide inside the
cylinder, remove tool n 400438 and apply the circlips 87x4 and A80x2,5L.
NOTE : All the seal seats must be thoroughly cleaned before assembly and lubricated with a light film of oil.
Seal assembly will be facilitated if the seals are preheated to a temperature of 40-60 colsius degrees
by immersing them in oil or exposing them to an infrared lamp.

- 28 -

STEERING CYLINDER ASSEMBLY 277 - 279

T. 45

T. 45

T. 45

T. 45
T. 45

T. 45

- 29 -

REPLACING THE LIP SEALS

To remove, carry out the
assembly operations in reverse
order without using special tools.

Heat the seals in oil to ~ 80 90C

(See page before).

Assemble the cylinder after

having changed all the lip seals.

STEERING CYLINDER ASSEMBLY 277 - 279

Check that the steering cylinder
piston rod is at half travel by
measuring from both sides with a
gauge or equivalent template.
Check parallelism between both
wheel hubs at approx. 500 mm
from the hub centre (front and
rear).

T. 37

Adjusting
the
parallelism
tightenings of safety clamps.

Adjusting the steering angle with

the relative template.

T. 3944

Adjust the steering angle with

end of travel screws.
279
L1

22mm 40
17mm 50

- 30 -

277
L1

18mm 50
22mm 40
32mm 36
46mm 30

BEVEL PINION SUPPORT

Removal of bevel pinion support.

T. 07

T. 03-04

T. 19

- 31 -

Assemble the external races

taper roller bearings.
Check cover measurement "A".

BEVEL PINION SUPPORT

Determination of shim pack S1
for the preload of the taper roller
bearings S1 = B - C + X
X = Value to add in order to
obtain the correct preload of the
taper roller bearings.

Valeur X = See page 34.

T. 26

T. 26

Assembly of bevel pinion support

and seal.

Assembly with Loctite 242.

T. 03-04

- 32 -

Tighten the ring nut with a torque

wrench ; see solution on page 34.

BEVEL PINION SUPPORT

Checking the rotation torque.
A 150200 Ncm
B 150200 Ncm
C 120170 Ncm
D 120170 Ncm

Assembly of the lip seal and

tightening of flange nut with a
torque wrench.

part. X
T. 14

- 33 -

- 34 -

AXLE BEVEL PINION SUPPORT 277 - 279

Disassembly :
Take care to prevent damage to
the retention areas of the OR
rings when removing the
differential gear from the central
box.

T. 03-04

- 35 -

BEVEL PINION SUPPORT

Determination of shim pack S2
for adjustment of bevel pinion
position. Assembling of outer
races without shims. Insert tool
and verify after having set to zero
the gauge on a surface plate. The
difference is S2. Remove outer
race of taper roller bearing, insert
shims and reassemble the outer
race definitively.

T. 27

A
60

Assembly of outer races of taper

roller bearings.
T. 12

- 36 -

AXLE BEVEL PINION SUPPORT 277 - 279

T. 26

Determination of shim pack S1

for the preload of taper roller
bearings :
S1 = B - C + X
X = Value to add in order to
obtain the correct preload of the
taper roller bearings (see
exploded view drawing on page
34 -Solution D).

T. 26

T. 26

Assembly of bevel pinion support

and tightening of flange nut (see
exploded view drawing on page
34 -Solution D).
T. 13

T. 14

T. 03-04

For checking of torque (see page

33 -Solution D).

- 37 -

AXLE ADJUSTEMENT OF BEVEL GEAR SET 172 - 177 - 272

Determination of shim pack S2
for adjustement of bevel pinion
position :
S2 = (I + A) - (D + r)
(See schema page 40).

Assembly of bevel pinion support

with shim pack S2. Tighten the
screws by about 86 / 89 with a
torque wrench and using Loctite
270.

Assembling central axle housing.

NOTE : Be careful not to damage
the tight surfaces of the
O-rings while inserting
the differential case into
the central axle housing.

- 38 -

TAPER ROLLER BEARINGS OF DIFFERENTIAL

T.06

Screw in the adjusting nuts to

obtain approx.0.15 - 0.18 mm
backlash between the teeth of the
bevel gear set, without preloading
the taper roller bearings.
Check the rotating torque of
pinion and differential. Tighten
nut on opposite site to the crown
wheel to obtain a 35 - 45 Ncm
higher rotating torque on the
pinion.

T.06

Mark both ring nuts. To adjust the

backlash move ring nuts only.
Loosen the one on bevel crown
wheel side and tighten the
opposite one for the equal
measure if the backlash is too
low ; viceversa if the backlash is
too high.

Mount locking tabs in the best

position and punch in place.

- 39 -

- 40 -

- 41 -

ADJUSTING BEVEL GEAR SET 172 WITHOUT BRAKE

Disassembly.

ASSEMBLY AND ADJUSTMENT

Insert an initial shim thickness of
0,8 mm on the crown wheel side
and 0,85 mm on the opposite
side.

Mount the differential with the

lateral axle housings, leaving the
bevel gear side nuts loose.
Check rotational torque of bevel
pinion.

Tighten all nuts of the lateral axle

housing.
Seat the taper roller bearings of
the differential by tapping on both
sides bon the axle shafts while
turning the pinion.

- 42 -

ADJUSTING BEVEL GEAR SET 172 WITHOUT BRAKE

Check the rotation torque of the
pinion which must be increased
by 3545 Ncm.
If corrections are required,
remove or add shims to
respectively decrease or increase
the rotation torque.

Check the backlash between the

teeth of the bevel gear pair gap =
0,18 0,25 mm.
If corrections are required, move
the shims from one side to the
other until the correct play is
obtained. EG. : Excessive play :
remove the shims from the side
opposite the ring bevel gear and
insert them on the ring bevel gear
side.

Check lateral axle housing

levelness after assemble.

- 43 -

DISASSEMBLY OF DIFFERENTIAL
Removal of the differential from
the axle.

NOTE : Replace the fitting bolts

of the crown wheel every
time that they have to be
removed.

- 44 -

ASSEMBLY OF THE DIFFERENTIAL

Insert the spring pins half way up
the pin.

Torque all bolts M10x1,25x25,

with a torque wrench clamping
torque 73 Nm.
M 12x30 bolts clamping torque
89 Nm. Use loctite 270.

- 45 -

SELF LOCKING DIFFERENTIAL

Check the disc pack to determine
the shims.
The total thickness of the disc
pack with eventual shims must be
16,2 0,1 mm.

Torque the bolts with a torque

wrench.
M10x40-10 K tightening torque
69 72 Nm ; use loctite 242.

- 46 -

CONVERSION TABLES

1 Atm 1 bar 10 Pa 14.4 Psi

Pa

da N

KN

Kg

Lbs

1N

0,1

0,001

0,102

0,225

1 da N

10

0,01

1,02

2,25

1 KN

1000

100

102

225

1 Kg

9,81

0,981

0,00981

2,205

1 Lbs

4,44

0,444

0,00444 0,4536

Nm

da Nm

KNm

Kgm

Lb-in

1 Nm

0,1

0,001

0,102

8,854

1 da Nm

10

0,01

1,02

88,54

1 KNm

1000

100

102

8854

1 Kgm

9,81

0,981

0,00981

86,8

1 Lb-in

0,1129 0,01129 0,0001129 0,01152

1 Kg cm 0,0981 0,00981 0,0000981

0,01

TIGHTENING TORQUES

Size of bolt

8.8

10.9

12.9

M4

2,9

4,1

M6

10,0

14,0

M8

25,0

35,0

M 10

49,0

69,0

M 10x1,25

52,0

73,0

88,0

M 12

86,0

120,0

M 14

135,0

190,0

M 14x1,5

150,0

210,0

250,0

M 16

210,0

295,0

M 18x1,5

325,0

460,0

550,0

A 22

550

- 47 -

1
0,868

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

Insufficient braking

1. Incorrect adjustment

Inspect disc thickness (see page 6)

and if discs are usable readjust
brakes to the specifications in the
vehicle's manual.

2. Brake discs worn out

Inspectdisc thickness (see page 6)

and replace if necessary.

3. Incorrect brake fluid

Replace all seals in axle and master

cylinder that have made contact with
the incorrect fluid and all brake
hoses.
If incorrect fluid leaked into axle oil,
seals and o-rings in axle must be
replaced.

4. Loss of brake fluid

Inspect for and repair any leaks in

outside circuit or master cylinder.
If caused by incorrect brake fluid see
correction N 3.
If leak is to the outside replace the orings between the center and
intermediate housings.
If leak is to the inside replace above
o-rings and brake piston o-rings.

5. Overheated axle causing brake

fluid to vaporize (brake return
when axle cools).

See "overheating" problem.

6. Air in brake circuit

Bleed brakes as described in the

vehicle's service manual.

Soft brake pedal

- 48 -

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

Overheating

10. Oil level wrong

Drain, flush and refill oil to proper

level.

11. Too small of a brake gap

Readjust brakes to the specifications

in the vehicle's service manual.

12. Park brake dragging

Unlock the brake and adjust tre

correct gap.

13. Incorrect brake fluid in system

See correction N 3.

14. No free-pedal at master cylinder

Readjust brake pedal as described in

the vehicle's service manual.

15. Restriction in brake lines

Inspect for and replace damage lines.

16. Restriction in return line

of brake Servo system

Inspect for and replace damaged

return line.
Inspect for and remove any filter,
tee'd in line or any other source of
back pressure from the return line.

17. Incorrect lubricant

Change the retaining rings of the

brake circuit and brake pump.

Noise during coast and

under power the same

26. Wheel bearings damaged

Replace and adjust as described on

page 17.

Noise under power greater

than during coast

27. Low oil level

Refill oil to proper level.

28. Incorrect lubricant

See correction N 17.

29. Ring and pinion worn

Inspect throught rear cover.

Replace and adjust as described from
page 31 to 39.

30. Worn ring and pinion bearings

Replace and adjust as described from

page 31 to 39.

- 49 -

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

31. Worn planetary gears or bearings

Replace as described on page 16.

32. Loose pinion nut

Inspect ring, pinion and pinion

bearings. If undamaged retighten nut
as described on page 32 and 33.

33. Only one pinion bearing

is damaged

See correction N 30.

Noise during turn (without NoSpin)

34. Worn spider and/or side gears

Replace as described from page 44.

A Stick slip noise when

going from forward to reverse

38. Spider pins loose in diff-carrier

Inspect and replace as described

from page 44.

39. Damaged or missing spider

and/or side gear washers

See coorection N 34.

Noise during coast greater than

under power

- 50 -

- 51 -

SPECIAL TOOLS

- 52 -

SPECIAL TOOLS

- 53 -

SPECIAL TOOLS

- 54 -

SPECIAL TOOLS

- 55 -

SPECIAL TOOLS

- 56 -

SPECIAL TOOLS

- 57 -

SPECIAL TOOLS

- 58 -

SPECIAL TOOLS

- 59 -

SPECIAL TOOLS

- 60 -