Gearbox ZF (5871 693 012 AS-2025-2075)

Ordering-No.
: 5871 693 012
ZF-PLANETARY STEERING
AXLE
VERSION
2025/2035/2045/2055/2060/2075
ZF Passau GmbH
Donaustr. 25 – 71
D - 94 034 Passau
Edition: 2001/01
REPAIR INSTRUCTIONS
for the ZF – PLANETARY STEERING AXLES
VERSION
AS
2025/2035/2045/2055/2060/2075
INFORMATION TO THE REPAIR INSTRUCTIONS
These instructions for the assembly and disassembly represents the state of construction of the ZF
planetary steering axle at the time of preparing the workshop manual.
The technical further development as well as extensions regarding different execution variants can
require deviating working steps which can be performed without any problem – by qualified staff –
with the aid of the perspective representations in the respective spare parts lists.
The present instructions for the assembly and disassembly will become invalid with the publication of
the successor edition.
In this respect, the ZF Passau GmbH is not responsible for the positive knowledge of the user of the
instructions.
ATTENTION:
For the installation as well as for starting up of the unit, observe the information
and instructions given by the vehicle manufacturer!
ZF Passau GmbH
Donaustr. 25 - 71
94034 Passau
Abt.: ASTDM / Section : ASTDM

Nachdruck auch auszugsweise ohne die Genehmigung der ZF Passau GmbH nicht gestattet!
Copyright ZF Passau GmbH!
Copying even partially not permitted!
Reproduction meme par extrait est interdite!
Technische Änderungen vorbehalten! With the reserve of technical modifications!
Sous reserve de modification techniques!
1.Auflage / 1.Edition
Geschäftsbereich
Workshop Manual Arbeitsmaschinen-Antriebe
und Achssysteme
PREFACE
This documentation has been developed for skilled staff trained by the Zahnradfabrik Passau for the repair
and maintenance works on ZF-units.
Documented is a ZF-serial product representing the design state at the time of the edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as different adjustments and testing specifications.
Therefore, we recommend to commit your ZF-product to foremen and technicians whose practical and
theoretical training is permanently updated in our after-sales service school.
The service stations established world-wide by the Zahnradfabrik Friedrichshafen are offering to you:
1. Continuously trained staff
2. Prescribed facilities, e.g. special tools
3. Genuine ZF-spare parts meeting the latest state of development
Here, all operations are carried out for you with utmost care and reliability.
Repairs carried out by ZF-service stations are covered by a respective warranty within the scope of
the applicable contractual conditions.
Damage caused by improper or unskilled work carried out by others than ZF-staff as well as resulting
consequential costs, if any, are excluded from this contractual liability.
This also applies, if the use of genuine ZF-spare parts is renounced.
ZF Passau GmbH
Service Department
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GENERAL
The Service Manual covers all works required for the disassembly and the pertaining assembly.
When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-
like manner. The transmission should only be disassembled for renewing damaged parts. Covers and
housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and
nuts have been removed. For removing parts being in tight contact with the shaft such as antifriction
bearings, bearing races and similar, use suitable pulling devices.
Disassembly and assembly works must be performed at a clean working place. Use the special tools
developed for that purpose. Prior to installing again the parts, clean the contact surfaces of housing and
covers from old sealing residues. Possibly formed burrs or similar irregularities must be removed with an oil
stone. Housing and cover must be cleaned with a suitable detergent, in particular in the corners. Parts which
are damaged or heavily worn down must be renewed. Here, an expert must assess, whether parts such as
antifriction bearings, stop discs etc., which are subjected to normal wear during operation, can be reused.
Parts such as sealing rings, retaining plates, split pins etc. must generally be renewed. Radial sealing rings
with worn down or torn sealing lip must also be renewed. Particularly make sure that no chips or other
foreign bodies remain in the housing. Lubricating oil bores and grooves must be checked for unhindered
passage.
Prior to their installation, all bearings must be treated with service oil.
REFE- For heating up parts such as bearings, housings etc, only a heating furnace or an electric
RENCE: drier is permitted to be used!
CAUTION
When assembling the transmission, absolutely observe the indicated torque limits and adjustment data.
Screws and nuts must be tightened according to the enclosed standard table, unless otherwise specified.
In view of possible functional failures, for transmissions, the use of liquid sealants as well as of Molykote in
the control unit is not permitted.
Discs with organic friction linings (e.g. paper discs) must not be washed (affecting the adhesion of the
lining).
They must be cleaned with a dry method (leather cloth).
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
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Structure of the Service Manual
The structure of this manual follows the sequence of the working steps for the complete disassembly of the
unit in dismantled condition.
Special tools required for the performance of the respective repair works are listed within the text as well as
in chapters "W" (List of special tools) and "WB" (Illustrated tool tables).
Important information concerning the work safety
Generally, the persons repairing ZF-units are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarise themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The persons in charge of the repair are obliged to perform the training.
The following safety references are used in the present Repair Manual:
You will always find this symbol in the present repair instructions
CAUTION where information regarding special working procedures, methods,
references, information on the use of working aids etc. are given.
This symbol indicates situations where lacking care can entail

DANGER damage to persons or the product.
____________________________________________
REFE- Prior to starting the checks and repair works, carefully read the present instructions..
RENCE:
REFE- illustrations, drawings and parts do not always represent the original; it is the working
RENCE: procedure which is shown.
The illustrations, drawings and parts are not represented true to scale; conclusions regarding
size and weight must not be drawn (not even within one representation).
The works must be performed according to the description..
REFE- After the repair works and the checks, the expert staff members must convince themselves
RENCE: that the product is properly functioning again..
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LUBRICATION- AND MAINTENANCE INSTRUCTIONS
1. Oil quality
Only oils are permitted to be used which have the qualification according to the ZF list of lubricants
TE - ML 05!
The ZF lists of lubricants are updated every two years and can be obtained or studied as follows:
- in all ZF-works
- in all ZF-After-Sales Service Centres
- Intranet http://web.zff.zf-group.de/ Documentation / Techn. Information
- Internet http://www.zf-group.de/ Documentation / Techn. Information
In the respective ZF list of lubricants, you will find information on the following:
Oil specification - Manufacturer - Product designation
such as
Transmission oils without and
with Limited-Slip additives etc. ....
Grease for lubricating points ...
2. Oil change
Drain oil with the axle at operating temperature and the vehicle in a horizontal position.
A further condition is the horizontal installation position – in either direction – of the axle.
All draining-, filling- and control screws must be thoroughly cleaned prior to opening.
2.1 Oil drain hole - output
To avoid injuries due to a possible pressure build-up

in the oil circuit of the planet carrier, bring filling- or
control screw (1) into the 'noon' clock position and
carefully unscrew it.
Then, bring drain bore into the '6 o'clock' position and 1
drain oil.
2.2 Oil filling - output

Bring filling bore into position (reference line
horizontal to the driving level, see arrow) and
fill in oil up to the overflow.
Place new O-ring onto screw plug (1) and.

mount it
Tightening torque . . . . . . . . . . . . MA = 150 Nm
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2.3 Oil drain hole – axle casing
Unfix drain plug (2) and drain oil.

3
2.4 Oil filling – axle casing
Provide drain plug (2)with new O-ring and mount it.

2
Fill in oil up to the overflow at the filling- or
control screw (3).
Provide filling- or control screw with new O-ring
and mount it.
After some minutes, check oil level and refill, if necessary, until the specified level is reached
and remains constant !
3. Oil changing interval:
1st oil change after 500 operating hours; every further change after 1000 operating hours, however at least
once per year.
3.1 Grease lubrication points:
Re-lubricate at the forced lubrication points - monthly (multi-purpose grease, lithium-saponified, NLGI-
class 2)
4. Breather:
For the axle versions with breather, the latter must be cleaned and subjected to a functional check within the
oil changing intervals as well as upon repairs.
5. Oil level check:
Oil level check every month, especially however upon starting the operation of a vehicle with new or
repaired axles or axle parts.
6. Oil (brake medium) for multi-disc brake (driven end):
For the pneumatic-hydraulically operated service brake control which can also be operated via an
accumulator, the following oils are admitted:
1. Engine oil SAE 10 W acc. to Spec. MIL-L-2104 C, MIL-L-46152, API-CC, CD, SD, SE, SF, SF.
2. ATF oils (type A suffix A, Dexron II)
Attention! Other brake fluids are not permitted to be used!
7. Oil for steering system and hydr. 100 % lock of the differential:
As specified and directed by the vehicle manufacturer.

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TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG

EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE
GLEASON GEAR-TOOTH SYSTEM
EXEMPLES POUR LA DENTURE GLEASON
Ideales Tragbild d.h. die Ritzeldistanz stimmt
Ideal tooth-contact pattern i.e. pinion distance is correct
L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte
Bild / Figure 1/3/5 Bild / Figure 1
Schubflanke (Konkav)
Coast side (concave)
Côté poussé (concave)
Bild / Figure 2/4/6 Bild / Figure 2
Zugflanke (Konvex)
Drive side (convex)
Côté entraîné (convexe)
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Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden
Pinion distance must be increased Pinion distance must be decreased
La distance du pignon doit être augmentée La distance du pignon doit être diminuée
(+) (-)
Bild / Figure 3 Bild / Figure 5
Bild / Figure 4 Bild / Figure 6
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LETTERING OF THE TYPE PLATE
MIL-L-2105 D 05
LS/SAE 90
1 = Axle type
2 = Axle serial number
3 = ZF – parts list number
4 = Overall axle ratio / version with or without ZF multi-disc self-locking differential
5 = Oil type
6 = Oil quality
INFORMATION TO ITEM 6: See ZF list of lubricants for ZF-axles TE - ML 05 !
INFORMATION FOR SPARE PARTS ORDERING

When ordering genuine ZF-spare parts, the following information shall be included:
1. Axle type
2. Unit number
3. ZF – parts list number
4. Make and type of the vehicle
5. Designation of the spare part
6. Spare parts number
7. Kind of dispatch
REFERENCE: Items 1, 2 and 3 may be taken from the type plate.

If all information indicated above are given, wrong deliveries in connection with spare part orders will be
avoided.
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VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25.0 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2.205 lb ( pounds )
9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per squar inch lbf/in2 )
=
0.070 bar ( 0.071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0.264 Gallon ( Imp. )
=
4.456 Liter 1 Gallon ( Imp. )
=
1 Liter 0.220 Gallon ( US )
=
3.785 Liter 1 Gallon ( US )
=
1609.344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273.15 Kelvin
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Density lineaire en kg/m; Density superficielle en t/m2
Begriff Formelzeichen neu alt Umrechnung Bemerkungen

Unit Formula sign New old Conversion Note
Uniteo Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9.1 N
Force
Force
Arbeit A J (Joule) kpm 0.102 kpm = 1J = 1 Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW
Power 1 KW = 1.36 PS
Puissance
Drehmoment T Nm kpm 1 kpm = 9.81 Nm T (Nm)
Torque (Newtonmeter) =
Couple F (N) . r (m)
Kraftmoment M Nm kpm 1 kpm = 9.81 Nm M (Nm)
Moment (Force) =
Moment (Force) (Newtonmeter) F (N) . r (m)
Druck (Über-) pü bar atü 1.02 atü
Pressure = 1.02 kp/cm2
(Overpress) = 1 bar
Pression (Sur-) = 750 torr
Drehzahl n min
Speed 1
Nombre de Tours
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TORQUE LIMITS FOR SCREWS (IN Nm) AS PER ZF-STANDARD 148

Friction coefficient: µ total= 0.12 for screws and nuts without aftertreatment, as well as for phosphated
nuts. Tighten by hand!
If not otherwise specified, tightening torques may be taken from the following list:
Metric ISO-standard thread DIN 13, sheet 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.,5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 12. 185 215
M16 19. 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO fine thread DIN 13, sheet 13
Size 8.8 10.9 12.9

M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1,25 49 72 84
M 12 x 1,25 87 125 150
M 12 x 1,5 83 120 145
M 14 x 1,5 135 200 235
M 16 x 1,5 205 300 360
M 18 x 1,5 310 440 520
M 18 x 2 290 420 490
M 20 x 1,5 430 620 720
M 22 x 1,5 580 820 960
M 24 x 1,5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1,5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1,5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1,5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1,5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1,5 3450 4900 5700
M 39 x 3 3200 4600 5300
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LIST OF SPECIAL TOOLS FOR THE DISASSEMBLY AND ASSEMBLY
ZF – PLANETARY AXLE AS-2025/2035/2045/2055/2060/2075

Disassembly 1.
Disassembly Assembly Designation and application Part number

Chapt. / Fig. Chapt. / Fig.
1/01 Assembly carriage compl. with tilting device 5870 350 000
Fixture 5870 350 040
Universal use .
For clamping the axles AS – 2025/2035/2045 on the
assembly carriage .
Fixture 5870 350 089
Clamping braces 1 set = 2 units 5870 350 075
Clamping bolts 1 set = 2 units 5870 204 059
Universal use .
assembly carriage .
1/05 AS-2025/ AS-2035/ AS-2045 5870 000 077

Press-off tool 5870 000 079
Fork
For pressing the track rod end off the joint housing .
AS-2055/ AS-2060/ AS-2075
Press-off tool 5870 080 041
For pressing the track rod end off the joint housing .
1/06 Hot-air blower 230 V 5870 221 500

Hot-air blower 115 V 5870 221 501
Universal use .
For heating up housing and bearing parts.
1/07 Slotted nut wrench 5870 401 128

For unfixing and tightening the slotted nut M 65 x 2
0501 315 404 at the cylinder .
Repair kit 0501 298 194 / 211 / 310
Cylinder 0501 209 522 / 693 / 695
Cylinder 0501 210 313
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Disassembly 1.

1/08 Plastic mallet ø 60 mm 5870 280 004

1/10 Universal use .
1/61 For the saving disassembly and assembly of sensitive parts
1/110
1/09 . 1/17 External pliers set A1-A2-A3-A4 5870 900 015

1/22 . 1/26 Universal use .
1/36 . 1/51 For removing and mounting of externally clamping
1/60 retaining rings .
1/18 Two-armed puller Range 120 5870 970 002

Universal use .
For extracting the planetary gears from the planet carrier.
1/20 . 1/40 General purpose spoon 2 units required ! 5870 345 071
1/63 . 1.120 Universal use .
1/129 For pressing the bearing inner ring off the planet carrier .
For removing the shaft sealing ring from the axle casing..
1/24 Clamping pliers 5870 900 021

Universal use.
For removing and mounting the retaining ring 92 x3
0630 502 075 from/into the internal gear .
1/28 Puller screws M 10 5870 204 005

1/32 Puller screws M 12 5870 204 012
Universal use .
For forcing the internal gear off the joint housing
1/29 Only for version with multi-disc brake !

Spring hook 5870 281 029
For suspending and unfixing the springs 0632 039 025
in the internal gear – piston resetting.
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Disassembly 1.

1/30 General purpose spoon 2 units required 5870 345 071
1/47 For separating various components such as shaft sealing
1/63 rings, bearings, flanges etc.
1/35 Mounting lever 1 set = 2 units 5870 345 036

Universal use .
For separating various components such as shaft sealing
rings, bearings, flanges etc.
1/35 For tight seat of bearing inner ring:

AS-2025/2035 Bearing: 0750 117 635
Rapid grip 5873 013 015
For extracting the bearing inner ring 0750 117 635 from
the joint housing.
Can be used in combination with :
5873 003 001
AS-2045 to 2075 Bearing: 0750 117 570
Grip
For extracting the bearing inner ring 0750 117 570 from 5873 004 026
the joint housing.
5873 004 001
1/42 Internal extractor Ø 45 – 58 mm 5870 300 007

1/65 For separating the bearing outer ring from the axle casing.
1/121 Can be used in combination with
Counter support 5870 300 003
1/58 Cutting-off fixture 5870 300 024

For separating the bearing inner ring from the bearing
bolt.
1/64 External pliers set I1-I2-I3-I4 5870 900 013

Universal use .
For removing and mounting of internally clamping
retaining rings.
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Disassembly 1.

1/68 Lifting strap 5870 281 026

Universal use .
For various lifting works .
1/70 Extracting tool 5870 650 004

1/71 Universal use.
1/72 For removing the bearing inner ring 0750 117 289 .
1/73 For removing the bearing inner rings 0750 117 445/589 .
For removing the piston 4481 346 070 .
1/74 Grip DZ - 250 5873 001 033

the differential cage 4131 302 098 .
Can be used in combination with:
Forcing insert 5870 026 100
Pressure piece 5870 100 041
1/81 Grip DZ - 400/500 5873 001 020

For extracting the bearing inner ring 0750 117 569 / 024
from the differential cage 4131 203 035 .
1/85 Grip DHL with DZ -250 5870 027 016

For extracting the bearing inner ring 0735 371 053 =
32014 from the cover 4481 345 033 .
Basic tool 5873 002 001
Grip 5873 001 033
For extracting the bearing inner ring 0750 117 289
from the differential cage 4131 302 098 .
1/87 Internal extractor Ø 36 to 46 5870 300 005

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Disassembly 1.

Universal use.
For removing the sliding sleeve 4481 346 040 from the
differential cage .
Can be used n combination with:
1/90 Grip DHL with DZ –400/500 5870 027 016

27690 from the cover 4481 346 077 .
Basic tool 5873 002 001
Grip 5873 001 020

1/100 Grip DHL with DZ – 750 5873 002 031

32020X from the cover 4475 310 024 .
Basic 5873 002 001
Grip 5873 001 059
1/115 Clamping fork # 5870 240 025

Universal use .
For fixing the input flange upon loosening and tightening
of the pinion screw joint.
1/119 Version „A“ AS – 2025 / 2035
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Disassembly 1.

Grip 5873 001 031
HM803149 from the bevel pinion.
AS – 2045 to 2075
Grip 5873 001 037
JW5049 or 0750 117 179 = HM80749 from the bevel
pinion.
1/121 AS – 2045 to 2075

Internal extractor Ø 70 – 100 mm 5870 300 019
Universal use .
For separating the bearing outer ring 0750 117 354 = HM
803 110 / 0750 117 088 = 31308 from the axle casing.
1/124 Version „B“ AS – 2025 / 2035 / 2045
Counter holder # 5870 240 037

For fixing the input pinion – input flange 4475 306 176
upon loosening and tightening of the pinion screw joint.
AS – 2060
Counter holder # 5870 240 038
For fixing the input pinion – input flange 4475 317 041
upon loosening and tightening of the pinion screw joint
1/126 Two-armed puller 5870 970 005

Universal use .
For separating the input pinion from the axle housing.
AS – 2025 / 2035
1/126 Grip 5873 001 031
HM803149 from the bevel pinion.
AS – 2045 – 2070
1/126 Grip
For extracting the bearing inner ring 0750 117 355 = 5873 001 037
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Disassembly 1.

JW5049 or 0750 117 179 = HM80749 from the bevel
pinion.
AS – 2025 / 2035
1/127 Internal extractor Ø 45 – 58 mm 5870 300 007
Universal use .
For separating the bearing outer ring from the axle
casing.
AS – 2045 – 2070
Internal extractor Ø 70 – 100 mm 5870 300 019
Universal use .
For separating the bearing outer ring 0750 117 354 =
HM 803 110 / 0750 117 088 = 31308 from the axle
casing.
Can be used in combination with: 5870 300 020
Counter support
1/134 Pliers set A11-A21-A31-A41 5870 900 016

For removing and mounting externally clamping
retaining rings
1/135 Two-armed puller 5870 970 003

Universal use .
For separating the sealing holder 4475 306 139 from
the axle casing.
1/138 Slotted nut wrench 5870 401 145

For loosening and tightening the slotted nut 0737 502
011 at the bevel pinion .
Only to be used in combination with :
Splined bush B 38 x 34 5870 512 013
1/140 Three-armed puller 5870 971 003

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Disassembly 1.

For separating various components . Bush 4475 306
201
1/145 Version „C“ AS – 2025 / 35 / 45 / 55 / 75
Cutting off fixture 5870 300 028

Universal use .
For separating various components .Bush 4475 306
174
1/148 Hot-air blower 230 V 5870 221 500

Hot-air blower 115 V 5870 221 501
Universal use.
For heating up of components .
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Assembly 2

Fixture 5870 350 040
Universal use .
assembly carriage .
Fixture 5870 350 089
Clamping braces 1 set = 2 units 5870 350 075
Clamping bolts 1 set = 2 units 5870 204 059
Universal use .
assembly carriage .
2/04 Abutting blocks 1 set = 2 units 5870 200 066

Digital depth gage 200 mm 5870 200 072
For various measuring procedures .
2/06 Assembly fixture # AS-2025/2035 5870 345 049

For drawing the bearing outer ring 0750 117 354 = HM803 110
into the housing bore.
2/06 Assembly fixture # AS-2025bis 2075 5870 345 049

Pressure ring # 5870 345 056
For drawing the bearing outer ring 0750 117 355 = JW5049
0750 117 179 = HM 807 010 into the housing bore .
2/07 Support AS-2025/2035 5870 058 062

For driving the bearing outer ring 0750 117 331 – HM 88
610 into the housing bore .
Grip 5870 260 002
Support AS-2025/35/45/55/60/ 5870 058 083

For driving the bearing outer ring 0750 117 088 – 31308
into the housing bore .
Grip 5870 260 002
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Assembly 2

2/07 Support AS-2075 5870 058 061
For driving the bearing outer ring 0750 117 354 – HM
803 110 into the housing bore .
Grip 5870 260 002
2/12 Counter holder # AS-2025/35/45 5870 240 037

2/14 For fixing the input flange 4475 306 176
Counter holder # AS-2060 5870 240 038

For fixing the input flange 4475 317 041
Clamping fork # 5870 240 025

For fixing the input flange
4472 352 084 / 4472 363 063
4475 304 101/131
4475 305 075/196/ 251/289/308
Slotted nut wrench # 5870 401 145

For unfixing and tightening the pinion screw connection
for version with slotted nut 0737 502 011
Splined bush # 38 x 34 5870 512 013

For fixing the pinion shaft = bevel gear set 4475 205
049 / 4475 206 018 / 4475 207 004
2/15 Torque wrench ¼“-4kt 100 – 500 Ncm 5870 203 019
Universal use.
For checking the rolling resistance of the pinion bearing
Reducer ¼“ to ½“ 5870 656 056
Reducer ½“ to ¾“ 5870 656 057
2/20 . 2/38 Dial gage # 5870 200 057

2/51 Magnetic stand # 5870 200 055
2.125 For various measuring tasks .
2/36 External pliers set A1-A2-A3-A4 5870 900 015

5871 693 012 W2/2
Geschäftsbereich
und Achssysteme

Assembly 2

2/103 Facilitates the assembly of the two differential case halves
.
For mounting and removing of externally clamping
retaining rings
2/65 Load cell 0 – 60 KN 5870 700 004

2/97 Digital depth gage 200 mm 5870 200 072
Universal use .
For pressing the disc pack for the determination of setting
„A“
2/66 , 2/90 Measuring ledge # 285 mm 5870 200 108

2/98 Abutting blocks # 1 set = 2 units 5870 200 066
2/119 Digital depth gage # 200 mm 5870 200 072
2/214 For various measuring procedures .
2/69 Pressure piece DHL/DZ250 DHL-400 5870 506 064

Pressure piece DHL/DZ250 DHL-400 5870 100 009
For protecting the bearing inner ring during the
installation of the second bearing point at the
differential case.
2/108 Adjusting screws 1 set = 2 units 5870 204 025

Universal use .
As assembly aid for mounting the crown gear to the
differential housing .
2/111 Pressure piece 5870 506 058

For protecting the bearing inner ring during the
installation of the second bearing point at the
differential housing.
2/122 Adjusting screws 1 set = 2 units 5870 204 022

Universal use . M 14
5871 693 012 W2/3
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und Achssysteme

Assembly 2

As assembly aid when mounting axle casing I to axle
casing II .
Adjusting screws 1 set = 2 units 5870 204 023

Universal use . M 16
casing II..
Adjusting screws 1 set = 2 units 5870 204 026

Universal use. M 18
casing II.
2/123 HP-pump # 5870 287 007

Functional check of the 100% lock and multi-disc brake
2/128 Support # IM = 15.1 5870 048 158

2/129 For inserting the shaft sealing ring 0750 111 176 = 50
x 80 x 10/10,5 into the axle casing .
Support # IM = 15.1
For inserting the shaft sealing ring 0750 111 177 = 5870 048 173
45 x 70 x 10 into the axle casing .
2/130 Support # IM = 2.0 5870 048 120

For inserting the shaft sealing ring 0750 110 045 =
60 x 90 x 10/14,5 into the axle casing .
Support # IM = 17.1
for inserting the shaft sealing ring 0634 390 091 = 5870 048 234
65 x 90 x 10/12 into the axle casing .
2/130
Support # IM = 13.5
2/135 For inserting the combination sealing ring 0750 111 448 = 5870 048 214
2/136 Support # IM = 2.0 5870 048 120

For inserting the multi-purpose sealing ring 0750 110 045
5871 693 012 W2/4
Geschäftsbereich
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Assembly 2

2/138 Counter holder # Ø 85 mm 5870 240 037

For fixing the input flange 4475 306 176 upon loosening
and tightening of the pinion screw connection
2/138 Counter holder # W62x2x30x9h 5870 240 038

For fixing the input flange 4475 317 041 upon loosening
and tightening of the pinion screw connection.
2/141 External pliers set A-11/A-21/A-31/A-41 5870 900 016

2/147 Universal use.
For mounting and removing externally clamping retaining
rings.
2/142 Support # IM = 6 + 0.5mm 5870 048 248

2/143 For inserting the combination sealing ring 0750 111 448 =
SSR 48 x 80 x 10/15,5 into the sealing holder
4475 306 139 .
2/142 Support # IM = 5,6 + 0.2mm 5870 048 249

2/145 For placing the combination sealing ring 0750 111 448 =
race onto the bush 4474 306 212 .
2/154 Support # IM = flush 5870 048 156

For inserting the bush 0501 315 509 = 40 x 44 x 40 into
the axle casing .
2/154 Support # IM = flush 5870 055 113

Without part 2
For inserting the bush 0501 316 251 = 52 x 56 x 40 into
the axle casing .
2/157 Support # in combination with: 5870 048 156

5871 693 012 W2/5
Geschäftsbereich
und Achssysteme

Assembly 2

Support # IM = flush 5870 048 157
For inserting the shaft sealing ring 0734 309 278 = 0750
110 137 = 40 x 44 x 40 into the axle casing .
2/157 Support # AS-2075 IM = flush 5870 055 113

With part 2
For inserting the shaft sealing ring 0750 110 139 = 60 x
82 x 25 into the axle casing .
2/166 Support # 5870 058 047

For inserting the bearing outer ring 0750 117 308 = M 86
610 into the axle casing .
Support # AS-2060/2075 5870 058 062

For inserting the bearing outer ring 0750 117 205 = HM 88
610 into the axle casing .
Grip 5870 260 002
2/167 Internal pliers set I1-I2-I3-I4 5870 900 013

Universal use
For mounting and removing internally clamping retaining
rings..
2/171 Support # IM = 2.5mm 5870 048 155

For inserting the shaft sealing ring 0750 110 153 = 53 x
78 x 14,7/17 into the joint housing .
2/171 Support # 5870 048 155

In combination with:
Support # AS – 2045/55 IM = 2.5 + 0,2 5870 048 172
For inserting the shaft sealing ring 0750 110 162 = 66 x 91
x 14,7/17 into the joint housing .
2/171 Support # AS-2960/75 IM = 4,0 + 0,2 5870 048 205

For inserting the shaft sealing ring 0750 110 162 = 66 x 91
5871 693 012 W2/6

Geschäftsbereich
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Assembly 2

x 14,7/17 into the joint housing
2/173 Pressure piece # 5870 506 097

2/174 For pressing the screening sheet 4475 305 082 / 4475 307
028 and the bush 4475 305 098 / 4475 306 112 onto the
articulated shaft .
Pressure piece # AS – 2075

For pressing the screening sheet 0501 211 418 and the 5870 506 145
bush 4475 308 008 onto the artic fork 0501 211 413 / =
Articulated shaft 0501 006 312 .
2/176 Internal extractor # 5870 300 005

In combination with :
Counter support # 5870 300 003
Universal use .
For introducing the double articulated shaft into the joint
housing.
2/179 Support # 0.4 mm 5870 048 154

2/180 For pressing the shaft sealing ring 0750 110 154 onto
the bearing bolt.
Support # Installation flush 5870 048 251

For pressing the shaft sealing ring 0734 309 369 onto
the bearing bolt.
Support # 0.4 mm AS-2055 / 2060 / 2075 5870 048 204

For pressing the shaft sealing ring 0750 110 154 /
0734 309 390 onto the bearing bolt.
Support # Install. flush AS-2055 / 2060 / 2075 5870 048 252

For pressing the shaft sealing ring 0750 110 154 /
0734 309 390 onto the bearing bolt.
5871 693 012 W2/7

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Assembly 2

2/186 Wrench # 5870 656 004

In combination with:
Torque wrench # 5 – 45 Nm 5870 203 033
Universal use.
For checking the rolling resistance in the swivel
bearing of the joint housing.
2/187 Wheel bolt extractor – Basic tool 5870 610 010

In combination with :
Insert M 18 x 1.5 5870 610 004
Wheel bolt 4472 351 456 / 508 , 4475 305 325 , 4475 359
129
Insert ¾ - 16 UNF 5870 610 005
Wheel bolt 4475 305 301 / 349
Insert M 20 X 1.5 5870 610 003
Wheel bolt 4475 317 076
Insert M 22 X 1.5 5870 610 002
Wheel bolt 4466 353 148
2/189 Support # 5870 051 035

For mounting the shaft sealing ring 0750 110 155 / 0750
110 163 / 0734 309 386 into the hub bore .
Grip 5870 260 004
Only for version with multi-disc brake ! 5870 347 018

2/197 Slip bush # AS – 2035
For mounting the piston 4475 306 224 into the internal
gear 4472 239 106 .
Slip bush # AS – 2045 5870 347 019

For mounting the piston 4475 306 224 into the internal
gear 4475 306 221 .
Slip bush # AS – 2060

For mounting the piston 4475 317 062 into the internal 5870 347 017
gear 4472 239 104 .
5871 693 012 W2/8

Geschäftsbereich
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Assembly 2

2/201 Spring hook # Only for multi-disc brake 5870 281 029
For hooking and unhooking the recoil springs in the
internal gear carrier.
2/202 Lever riveting tongs # 5870 320 016

Universal use .
For locking the oil supply bores with plugs.
2/206
2/209 External pliers set A1-A2-A3-A4 5870 900 015
2/223 For removing and mounting of externally clamping
2/256 retaining rings.
2/212 Clamping pliers # Only for multi-disc brake 5870 900 021
Universal use .
For removing and mounting the retaining ring in the
internal gear.
2/216 High-pressure pump # 5870 287 007

2/274 Mini-measuring coupling *** M 16 x 1.5 5870 950 103
Mini-measuring coupling ** M 14 x 1.5 5870 950 102
Mini-measuring coupling * M 12 X 1.5 5870 950 101
For function testing of the multi-disc brake, steering ***
Connection to * hollow screw 4475 305 392 .
Connection to ** joint housing 4475 305 392 .
2/235 Plug gage # 5870 200 071

For determining the setting measure for the inductive
transmitter 0501 208 843 in the axle casing .
Digital depth gage 5870 200 072
5871 693 012 W2/9

Geschäftsbereich
und Achssysteme

Assembly 2

2/243 Indicator 5870 221 152

Adapter cable 5870 221 144
For functional check of the inductive transmitter / steering
lock
2/269 Slotted nut wrench # 5870 401 128

For loosening and tightening the slotted nut M 65 x 2
0501 315 404 at the steering cylinder .
Repair set 0501 298 194 / 211 / 310
2/273 Measuring ledges # 1 set = 2 units 5870 200 029

Measuring device # 5870 200 033
For determining the track setting and the steering angle.
2/274 Flange holder # Input Version „B“ 5870 240 041

For fastening the measuring device 5870 200 033 on the
input flange 4475 306 176 / 4475 317 041
2/285 Support # 5870 048 250

For inserting the breather 0501 210 151 into the axle
casing .
5871 693 012 W2/10

Workshop Manual
Geschäftsbereich
Arbeitsmaschinen-Antriebe
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WB/1
Workshop Manual
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WB/2
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WB/3
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WB/10
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WB/11
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WB/12
Workshop Manual
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WB/13
WorkshopManual
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WB/14
Workshop Manual
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WB/15
Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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WB/19
Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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Workshop Manual
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1. DISASSEMBLY
Mount axle onto assembly carriage.
Axle type - AS 2025/2035/2045

(S) Assembly carriage 5870 350 000
(S)Fixture 5870 350 040
Fig. 1
Mount axle onto assembly carriage.
Axle type - AS 2055/2060/2075

(S) Assembly carriage 5870 350 000
(S) Fixture 5870 350 089
(S) Clamping brace 5870 350 075
(S) Clamping bolts 5870 204 059
Fig. 2
1.1 STEERING SYSTEM:
If required – depending on the axle type – remove stop screw.
Fig. 3
Unscrew hexagon nut.
Fig. 4
5871 693 012 1/1

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Unfix track rod from the joint housing using a press-off tool.
AS - 2025/2035/2045
(S) Press-off tool 5870 000 077
(S) Fork 5870 000 079
AS - 2055/2060/2075
(S) Press-off tool 5870 080 041
Fig. 5
On either side, separate complete track rod from the piston rod.
Track rod is inserted with Loctite (Type-No. 243) into the piston
rod – heat up, if necessary!
Hot-air blower 230 V 5870 221 500

Hot-air blower 115 V 5870 221 501
Mark installation position of the two track rods – assembly aid!

Fig. 6
Slide piston rod into the cylinder, until it is in full contact and
unscrew slotted nut (cylinder fixing).
(S) Slotted nut wrench (M65x2) 5870 401 128
Fig. 7
Withdraw complete steering cylinder from the axle casing.
(S) Plastic mallet 5870 280 004
Fig. 8
5871 693 012 1/2

Geschäftsbereich
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Remove retaining ring and O-ring arranged behind.
(S) External pliers set 5870 900 015
Fig. 9
Slide or push guide bush into the cylinder tube, until the snap
ring can be removed.
Fig. 10
Remove snap ring.
Fig. 11
Pull piston rod including guide bush off the cylinder tube.
Then, remove all sealing elements from piston rod, guide bush
and cylinder tube.
Fig. 12
5871 693 012 1/3

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1.2 OUTPUT:
Unfix plug and drain oil from the axle casing.
Fig. 13

Below, the entire disassembly of the output is represented; if
works on the differential and/or pinion are required, the
output can be disassembled as one unit – see adjacent
photograph.
Required working steps (e.g. disassembly of track rod,

bearing bolt etc... ) may be taken by excerpts from the
following description of the entire disassembly.
Observe shaft sealing ring in the axle casing – risk of

damaging
Fig. 14
1.2.1 PLANET CARRIER:
To avoid injuries due to a possible pressure build-up in the

oil circuit of the planet carrier, bring filler- or control screw
into the clock position 'noon' and carefully unscrew it!
Then, bring drain hole into position '6 o' clock' and drain oil!
Fig. 15
Unfix socket head bolts and withdraw planet carrier from the
hub.
Fig. 16
5871 693 012 1/4

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Remove retaining ring.
(S) Internal pliers set 5870 900 015
Fig. 17
Withdraw planet gears.
In the case of tapered-roller bearings (with plastic bearing cage),

observe released cylindrical rollers – also see Fig.-No. 21!
(S) Two-armed extractor 5870 970 002
Fig. 18
Version „A“
Planet gear support with cylindrical roller
bearing:
(Fig.-No. 19)
Remove angle ring and withdraw bearing inner ring (with

cylindrical rollers) from planet gear – only for version "with
supporting ring" – observe released supporting rings.
Fig. 19
Version „B“
Planet gear support with inclined roller bearing:
(Fig.-No. 20 ... No. 21)
Remove bearing inner ring.
(S) Multi-purpose spoon 5870 345 071
Fig. 20
5871 693 012 1/5

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Components of the inclined roller bearing:

2
1 1 = Bearing inner ring
2 = Cylindrical rollers
3 = Roller cage
3
Fig. 21
1.2.2 INTERNAL GEAR / MULTI-DISC

BRAKE:
1.2.2.1 VERSION "WITH" MULTI-DISC BRAKE:
Fig. 22
Withdraw disc carrier from the sun gear shaft or the disc pack.
.
Fig. 23
(S) Clamping pliers 5870 900 021
Fig. 24
5871 693 012 1/6

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Withdraw end shim and disc pack from the internal gear.
Fig. 25
Remove retaining ring from the sun gear shaft.
Fig. 26
Loosen bolt connection.
Hexagon bolts are inserted with Loctite (Type-No. 243) !
Fig. 27
Separate internal gear from the joint housing using a puller

screw..
Observe released O-ring!
(S) Puller screws (M 10) 5870 204 005

(S) Puller screws (M 12) 5870 204 012
Fig. 28
5871 693 012 1/7

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Clamp internal gear into vice.
Then, unhook all tension springs and remove both retaining

rings.
(S) Spring hook 5870 281 029
Fig. 29
Remove piston from internal gear.
Fig. 30
1.2.2.2 VERSION "WITHOUT" MULTI-DISC BRAKE:
Unfix screw connection.
Hexagon bolts are inserted with (Type-No. 243) !
Fig. 31
Separate internal gear from joint housing using a pulling screw.
(S) Pulling screws (M 10) 5870 204 005

(S) Pulling screws (M 12) 5870 204 012
Fig. 32
5871 693 012 1/8

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1.2.3 HUB:
Withdraw hub from joint housing using a two-armed extractor.
Observe released bearing inner ring!
Remove O-ring (arrow) from hub.
Fig. 33
Remove shaft sealing ring from hub.
If required, remove both bearing inner rings from the hub.
Fig. 34
Remove bearing inner ring from joint housing.
(S) Mounting lever 5870 345 036
Only in case of extremely tight bearing seat.

AS - 2025/2035 (Bearing 0750 117 635)
(S) Rapid grip 5873 013 015
(S) Basic tool 5873 003 001
AS - 2045/2055/2060/2075 (Bearing 0750 117 570)

(S) Grip 5873 004 026
(S) Basic tool 5873 004 001
Fig. 35
Spread retaining ring and withdraw sun gear from the double
articulated shaft.
Fig. 36
5871 693 012 1/9

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1.2.4 JOINT HOUSING – STEERING SENSOR

SYSTEM:
Only for version "with" plate:
Unfix screw connection and withdraw plate.
Fig. 37
1.2.4.1 SWIVEL BEARING :

1
6
1.2.4.1.1 BEARING BOLT VERSION „A“:
2 Standard version - (without steering sensor):
(Fig.-No. 38 ... No. 42)
5
Legend to Sketch:
4 1 = Bearing bolt
2 = Joint housing
3 = Axle casing
3 4 = Roller bearing
Fig. 38 5 = Shaft sealing ring
6 = Shim (only at the top bearing bolt)
Unfix screw connection of the two bearing bolts.
Fig. 39
Secure joint housing with a lifting facility and remove both

bearing bolts.
Observe released shims at the upper bearing bolt!
Fig. 40
5871 693 012 1/10

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Separate joint housing with double articulated shaft from the

axle casing.
Fig. 41
If required, withdraw bearing outer rings from the swivel bearing

bore of the axle casing.
(S) Internal extractor 5870 300 007

(S) Counter support 5870 300 003
Fig. 42
3 2
1.2.4.1.2 BEARING BOLT _ VERSION „B“:
1 Version - „with“ angle sensor:
10 (Fig.-No. 43 ... No. 54)
4
5
The sensor cover and the sensor housing must be
disassembled prior to disassembling the bearing bolts – risk
of damage!
9 7
6 Only one bearing bolt (equipped with sensor) is installed to
8 the axle casing (residual ones = standard version) !
11 Legend to Sketch:
Fig. 43 12
1 = Lock plate (only for version "with")
2 = Sensor cover
3 = Magnet carrier
4 = Sensor housing
5 = Bearing bolt
6 = Joint housing
7 = Axle casing
8 = Roller bearing
9 = Shaft sealing ring
10 = Shim (only at the top bearing bolt)
11 = Foot plate
12 = Locking cover
5871 693 012 1/11

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Unfix screw connections and withdraw lock plate (only for

version "with" lock plate).
Fig. 44
Withdraw sensor cover (with O-ring and compression spring and

remove magnet carrier.
Fig. 45
Pull sensor housing off the bearing bolt.
Unfix screw connection (arrow) at both bearing bolts.
Observe released bottom bearing bolt !
Fig. 46
Secure joint housing with lifting facility and remove both

bearing bolts.
Observe released shim at the top bearing bolt!
Fig. 47
5871 693 012 1/12

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Separate joint housing with double articulated shaft from the

axle casing.

damage!
Fig. 48
Pull bearing outer ring off the swivel bearing bore in the axle
casing.
Observe foot plate of the angle sensor.

Fig. 49
Unfix screw connection and separate plug connection (arrow) of

the cable.
Fig. 50
If required, remove retaining ring, separate cover with O-rings

and seal from the plug.
Fig. 51
5871 693 012 1/13

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Only for version "with" tube:

(Fig.-No. 52)
Withdraw O-ring and tube from the bore.
The tube can only be withdrawn and introduced with

disassembled double articulated shaft!
Fig. 52
Remove foot plate with both O-rings from the swivel bearing
bore
Fig. 53
If required, drive off cover (arrow)..
Fig. 54 1.2.4.1.3 BEARING BOLT – VERSION „C“:

A Version "with" dual sensors:
(Fig.-No. 55 ... No. 57)
Disassembly of the bearing bolt – as described for version
1
6
2 "A" – see Page 1/10, Fig.-No. 39 ..... Page 1/11, Fig.-No. 42 !
Legend to Sketch:
1 = Bearing bolt
5 2 = Joint housing
3 = Axle casing
4 = Roller bearing
6 = Shim (only at top bearing bolt)
3
4 At the axle casing, only one fork head/bearing bolt is
equipped with sensor (residual ones = standard version)!
Fig. 55
5871 693 012 1/14

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Legend to Sketch:
1 = Cover
2 = Inductive transmitter
3 = Indented ring
5 1 4 = Retaining ring
3 5 = Adjusting disc
Unfix cylindrical bolts, remove cover as well as indented ring

and withdraw inductive transmitter (with retaining ring and
adjusting disc).
2 4
Fig. 56
Legend to Sketch:
1
3 1 = Cover/cable harness
2 = Plug connection/cable harness
3 = Plug connection/sensor 1
4 = Plug connection/sensor 2
Unfix screw connection and withdraw cable harness (with cover)

until plug connection can be separated.
4 2
Fig. 57
Press bearing inner ring and shaft sealing ring off the bearing
bolt using a cutting-off fixture.
(S) Cutting-off fixture 5870 300 024
Fig. 58
Only for version "with" multi-disc brake:

(Fig.-No. 59)
Remove pressure connection and breather.
Fig. 59
5871 693 012 1/15

Geschäftsbereich
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Fig. 60
Drive double articulated shaft off the joint housing.
Fig. 61
Press bush and screen sheet off the double articulated shaft using
a cut-off fixture.
(S) Cut-off fixture 5870 300 024
Fig. 62
Remove shaft sealing ring from the joint housing.
Fig. 63
5871 693 012 1/16

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Remove retaining ring and withdraw ball bearing from the

bearing bore.
Fig. 64
Pull shaft sealing ring and bush off the bore / axle casing.

Fig. 65
Dismantle breather.
(Depending on the version – plug- or screw connection)
Fig. 66
5871 693 012 1/17

Geschäftsbereich
und Achssysteme
1.3 DIFFERENTIAL:
For works on the differential and/or pinion, the input(s) can
be disassembled as one unit – see adjacent photograph.
The necessary working steps (e.g. disassembling track rod,

bearing bolt etc...) may be taken by excerpts from section 1.1.
STEERING SYSTEM Page 1/1 ... Page ½ and section 1.2.4
JOINT HOUSING Page 1/10 ... Page 1/13!
Fig. 67
damaging!
Lift axle casing/Part II with a lifting facility, support axle

casing / Part I (arrow).
Unfix screw connection of the axle casing halves.
(S) Lifting strap 5870 281 026
Fig. 68
Separate axle casing/Part II from axle casing/Part I.
Observe released differential or parts of it!
Fig. 69
Only for differential version "D" and "DZ":

(Fig.-No. 70)
Pull bearing outer ring off the bearing bore and remove shim(s)
arranged behind.
Then, remove O-ring (see arrow).
(S) Extractor 5870 650 004
Fig. 70
5871 693 012 1/18

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Only for differential version " DHL with DZ " (100% lock):
(Fig.-No. and 72)
Pull bearing outer ring off the bearing bore and remove shim(s)
arranged behind.
Then, remove O-ring (see arrow)
(S) Extractor 5870 650 004
Fig. 71
Extract piston and remove both four-lip sealing rings.
(S) Extractor 5870 650 004
Fig. 72
Lift differential off the axle casing / Part I.
Then, pull bearing outer ring off the bearing bore of the axle
casing / Part I and remove shim(s) arranged behind.
Mark shim – assembly aid / assignment regarding the installation

position.
(S) Extractor 5870 650 004
Fig. 73
1.3.1 VERSION - "DZ 250":

(Multi-disc self-locking differential)
Withdraw both tapered roller bearings from the differential case.
(S) Grip "Super" 5873 001033

(S) Extractor insert 5870 026 100
(S) Pressure piece 5870 100 041
Fig. 74
5871 693 012 1/19

Geschäftsbereich
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Unfix cylindrical screws.
Fig. 75
Separate crown gear from the differential case using a forcing

screw..
Fig. 76
Withdraw disc pack with axle bevel gear from the differential
case.
Fig. 77
For the disassembly of the differential axle, drive clamping pin

into the axle (see Sketch-No. 1/79).
Fig. 78
5871 693 012 1/20

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Legend to sketch:
X = Position of the clamping pin for driving out the

differential axle
1 = Differential axle
2 = Clamping pin
3 = Differential case
X
Fig. 79
Drive out differential axle.
Withdraw differential bevel gears, thrust washer and second disc

pack with axle bevel gear from the differential case.
Remove clamping pin (see arrow).
Fig. 80
1.3.2 VERSION - "DZ 400/500":

(Multi-disc self-locking differential)
Withdraw both tapered roller bearings from the differential

basket.
DZ 400/500
(S) Grip 5873 001 020
(S) Pressing-off insert 5870 026 100
Fig. 81
Fix differential with a press and unfix cylindrical bolts.
Fig. 82
5871 693 012 1/21

Geschäftsbereich
und Achssysteme
Remove differential case half and remove accessible part.
Fig. 83
Press crown gear off the differential case half.
Fig. 84
1.3.3 VERSION - " DHL with DZ 250":

A (DHL = Diff. hydr. power shiftable - 100 % lock)
B
A = DHL –part
B = DZ - part
The disassembly of the DHL-part is largely identical to that
described for version DHL with DZ 400/500 – see section
1.3.4, Page 1/23 ... 1/25.
Disassembly of the DZ-part – see section 1.3.1, Page 1/19 ...
1/21.
Fig. 85
(S) Grip (crown gear side) 5873 002 035
(S) Basic tool 5873 002 001
(S) Grip 5873 001 033
5871 693 012 1/22

Geschäftsbereich
und Achssysteme
1.3.4 VERSION -"DHL with DZ 400/500":

(DHL = Diff. hydr. power shiftable - 100% lock)
Withdraw axial roller ring.
Fig. 86
Withdraw compl. sliding sleeve from the differential case

Fig. 87
Turn centering sheet, until recess (arrow) is in line with the

clamping pin of the sliding sleeve (arrow) – withdraw centering
sheet and plate spring.
Fig. 88
Withdraw snap ring (sliding sleeve fixing device) from the

cover.
Fig. 89
5871 693 012 1/23

Geschäftsbereich
und Achssysteme
Withdraw bearing inner ring.
(S) Grip 5870 027 016

(S) Basic tool 5873 002 001
Fig. 90
Withdraw second bearing inner ring.
(S) Grip 5873 001 020

(S) Extractor insert 5870 026 100
Fig. 91
Unfix crown gear screw connection.
Fig. 92
Withdraw cover.
Remove cage and levers.
Fig. 93
5871 693 012 1/24

Geschäftsbereich
und Achssysteme
Withdraw pressure ring, disc pack and end shim from the
differential case.
Fig. 94
Only for version "DHL 250":

2 Legend to Sketch:
1
3 2 = Disc pack /DHL-part
3 = Pressure ring
4 6 4 = Adjusting disc
5 = Snap ring
5 7 6 = Snap ring
8 7 = Pressure disc
8 = Disc pack/DZ-part
Fig. 95 Withdraw adjusting disc (Item. 4), remove snap ring (Item 5 and
6) and pressure disc (7).
Unfix screw connection.
Fig. 96
Withdraw differential case half and remove all parts.
Fig. 97
5871 693 012 1/25

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und Achssysteme
Press crown gear off the differential case.
Fig. 98
1.3.5 VERSION "DHL with DZ 750":
Withdraw axial roller cage.
Fig. 99
Withdraw bearing inner ring.
(S) Grip 5873 002 031

(S) Basic tool 5873 002 001
Fig. 100
Withdraw second bearing inner ring.
(S) Grip 5873 001 059

Fig. 101
5871 693 012 1/26

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und Achssysteme
Fix differential with a press and unfix screw connection cover /

crown gear.
Fig. 102
Withdraw cover and remove all components – see Fig.-No. 104 .
Fig. 103
Legend to Sketch:
1 1 = Differential case
5 2 = Cylindrical pins
3 = Disc pack DHL-part
2 4 = Disc pack
6 5 = Cover
3
6 = Cage
17 7 = Levers
8 = Disc
4 8
Fig. 104
Remove retaining ring, withdraw pressure spring and sliding

sleeve.
Fig. 105
5871 693 012 1/27

Geschäftsbereich
und Achssysteme
Unfix pressure ring screw connection.
Fig. 106
Withdraw pressure ring and disc pack from the differential case.
Fig. 107
Insert puller screw to press crown gear off the differential case
using a pressure plate.
Fig. 108
Legend to Sketch-No. 109 ..... Fig.-No. 111:

3 2
1 2 = Clamping pin
3 = Differential axle (split design - 2 units)
4 = Differential bevel gear
4 5 5 = Differential axle (one-piece design)
3 2
Fig. 109
5871 693 012 1/28

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und Achssysteme
Disassemble clamping pin (half-shaft fixing) – see Item-No. 2 /

Sketch-No. 109.
Disassembly aid – secure internal diameter of the clamping pin

against excessive squeezing using suitable cylindrical pins.
Disassemble second clamping pin – see arrow – applying the

same method.
Fig. 110
Press off half-shaft and remove differential bevel gear with

buffer disc.
Disassemble second half-shaft applying the same method.
Fig. 111
Withdraw one-piece differential axle and remove residual

differential bevel gears with adjusting spacer.
Fig. 112
Withdraw second disc pack with side gear from the differential
case.
Fig. 113
5871 693 012 1/29

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und Achssysteme
1.4 INPUT FLANGE / PINION:

4
1.4.1 VERSION "A":
1
Legend to Sketch:
5 1 = Axle casing
2 = Hexagon nut
3 3 = Input flange
2
4 = Pinion
Fig. 114
Unfix hexagon nut.
(S) Clamping fork 5870 240 025
Fig. 115
Withdraw flange and disc.
Fig. 116
Disassemble input pinion –if possible (depending on the axle

casing version) press it off using a two-armed extractor
When re-using the tapered roller bearings, during extracting, the

pinion must be kept in contact with the external bearing outer
ring.
Fig. 117
5871 693 012 1/30

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und Achssysteme
Withdraw spacer ring.
Fig. 118
Press bearing inner ring off the input pinion.
AS - 2025/2035
(S) Grip 5873 001 031
AS - 2045/2055/2060/2075
(S) Grip 5870 001 037
Fig. 119
Press off shaft sealing ring.

Remove bearing inner ring now accessible.
Fig. 120
Withdraw external bearing outer ring.
AS - 2025/2035
AS - 2045/2055/2060/2075
Fig. 121
5871 693 012 1/31

Geschäftsbereich
und Achssysteme
Drive bearing outer ring off the internal bearing bore.
Observe released adjusting spacer!
Fig. 122
4 1.4.2 VERSION "B":
1 Legend to sketch:
1 = Axle casing
5 2 = Hexagon nut
3 = Input flange
4 = Pinion
3 2
Fig. 123
Unfix hexagon nut.
AS - 2025/2035/2045
AS – 2060
Fig. 124
Remove disc and withdraw input flange.
Fig. 125
5871 693 012 1/32

Geschäftsbereich
und Achssysteme
Press input pinion off the axle casing.
AS-2060
Fig. 126
Remove spacer ring.
Fig. 127
Press bearing inner ring off the pinion.
AS - 2025/2035
(S) Grip 5873 001 031
AS – 2045/2055/2060/2075
(S) Grip 5873 001 037
Fig. 128
Press off shaft sealing ring and remove bearing inner ring now
accessible.
Fig. 129
5871 693 012 1/33

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und Achssysteme
Drive bearing inner ring off the internal bearing bore.
Observe released adjusting spacer!
Fig. 130
Withdraw bearing outer ring from the external bearing bore.
AS - 2025/2035
AS – 2060
Fig. 131
1.4.3 VERSION "C":
Legend to Sketch:
1 1 = Axle casing
2 = Protecting sleeve
3 = Retaining ring
4 = Bush
5 = Combination sealing ring
6 = Bush
7 = Retaining ring
8 = Locking nut
8 9 = Pinion
7
4 5
2
6
3
Fig. 132
5871 693 012 1/34

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und Achssysteme
Unfix screw connection and withdraw protection sleeve.
Fig. 133
(S) Pliers set 5870 900 016
Fig. 134
Withdraw complete bush.
Fig. 135
Legend to picture:
1 1 = Bush
2 2 = Shaft sealing ring
4 3 = Screening plate
4 = Bush
5 = O-ring
5 3
Fig. 136
5871 693 012 1/35

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und Achssysteme
Remove O-ring (arrow).

Remove second retaining ring.
(S) Pliers set 5870 900 016
Fig. 137
Unfix locking nut.
(S) Slotted nut wrench 5870 401 145

(S) Splined bush 5870 512 013
Fig. 138
Temporarily mount protection bush again.
Fig. 139
Press off input pinion.

Then, disassemble protection bush again.
(S) Three-armed extractor 5870 971 003
Further pinion disassembly – as described in section 1.4.2,

Page 1/33, Fig.-No. 127 ... Page 1/34, Fig.-No. 131 !
Fig. 140
5871 693 012 1/36

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und Achssysteme
1.5 SELF-ALIGNING BEARING:

1
2 2
1.5.1 VERSION "A":
(overhead self-aligning bearing)
Legend to sketch:
1 = Axle casing
2 = Bush
Withdraw bushes from the self-aligning bearing bore.
Fig. 141
1.5.2 VERSION "B":

2 1 3 (Double bearing support)
Legend to sketch:
1 = Axle casing
2 = Bearing support (front)
3 = Bearing support (rear)
Fig. 142
Withdraw both bearing supports from the axle casing.
Fig. 143
Remove individual components from the bearing support.

1
3 Legend to picture:
2
1 = Bearing support
2 = O-ring (only in the rear bearing support)
3 = Threaded bush
4 = V-ring
5 = Bush
5
4
Fig. 144
5871 693 012 1/37

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If required – heat up bush and withdraw it from the axle casing

using a device; remove buffer disc arranged behind.
In case of an extremely tight seat of the bushes, they must be

destroyed for being disassembled, if necessary (separating cut) !
(S) Cutting-off fixture 5870 300 028
(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501
Fig. 145
1.5.3 VERSION "C":

1 (unilateral axle support)
4 2
3
Legend to Sketch:
1 = Axle casing
2 = Protection bush
3 = Bush
4 = Bush
Fig. 146
Unfix screw connection and withdraw protection bush.
Fig. 147
If required – heat up bushes and withdraw them using a fixable

three-armed extractor.
In case of an extremely tight seat of the bushes, they must be

destroyed for being disassembled, if required (separating cut) !
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
(S) Three-armed extractor 5870 971 003

Fig. 148
5871 693 012 1/38

Geschäftsbereich
und Achssysteme
2. ASSEMBLY
2.1 INPUT PINION:
If the crown gear or input pinion should be damaged – both

parts (bevel gear set) must be renewed!
Bevel gear set = crown gear and input pinion, both parts
must have identical pair numbers!
2.1.1 Determine adjusting spacer for pinion

positioning for an optimal contact pattern
at the bevel gear set - see contact pattern
samples Page 0/06 and 0/07:
3 2
1
II
III
X S
I
Fig. 1
Legend to sketch and following calculation examples:
1 = Axle casing
2 = Adjusting spacer
3 = Tapered roller bearing
4 = Pinion
I = Measure "I" (Adjust. spacer contact/bore up to axle centre)

II = Measure"II" (Bearing contact/pinion up to axle centre)
III = Measure"III" (Bearing width)
X = Measure "II" + Measure "III"
S = Thickness of the required adjusting spacer
5871 693 012 2/1

Geschäftsbereich
und Achssysteme
Read measure "I" (position – depending on axle type), from the

axle casing (Part I).
145,10
Measure"I" e.g. ......................................... 145.0 mm
If no value for Measure "I" is specified on the axle casing,

determine Measure "I" (adjusting spacer contact/bore up to axle
centre) with suitable means – see Sketch-No. 1, Page 2/1 !
Fig. 2
Read or determine Measure "II" (pinion measure)
112 Pinion measure (basic distance e.g. ...................... 112.00 mm

74 if a ± distance deviation of e.g. + 0.10 mm
is specified
Measure "II " e.g. ............................................ = 112.10 mm

+ 0,10
Pair number/pinion e.g. (74) must be identical with pair

number/crown gear (bevel gear set) !
Fig. 3
Determine Measure"III" (bearing width).
Measure "III" e.g. ......................................... 32.15 mm
(S) Abutting blocks 5870 200 066

(S) Digital depth gage 5870 200 072
Fig. 4
CALCULATION EXAMPLE "A":

Measure "II" ........................................... 112.10 mm
Measure "III" ......................................... + 32.15 mm
Result: Measure "X" .... ........................... = 144.25 mm
CALCULATION EXAMPLE "B":

Measure "I" ............................................ 145.10 mm
Measure "III" ........................................ – 144.25 mm
Result:→ Adjusting spacer "S" = 0.85 mm
5871 693 012 2/2

Geschäftsbereich
und Achssysteme
Insert determined adjusting spacer (e.g.. s = 0.85 mm) into the

inner bearing bore.
Fig. 5
Undercool bearing outer ring (see arrow) and bring it into

contact using a device.
Roller bearing 41.275x88.9x30.162

(S) Assembly fixture 5870 345 049
Roller bearing 50x105x32 and 53.9x104.7x36.5

(S) Assembly fixture 5870 345 049
with pressure ring 5870 345 056
Fig. 6
Undercool external bearing outer ring and insert it, until it is in

contact.
Roller bearing 40x90x25.25

(S) Support 5870 058 083

(S) Support 5870 058 062

(S) Support 5870 058 061
Fig. 7
Heat up tapered roller bearing and line it up, until it is in contact.
Re-adjust tapered roller bearing when it is cooled down!
Fig. 8
5871 693 012 2/3

Geschäftsbereich
und Achssysteme
2.1.2 Set rolling moment of the input pinion

bearing 1.0 ...2.0 Nm (without shaft
sealing ring):
Line up spacer ring (s = optionally).
It is recommended to re-use the spacer ring found upon

disassembly; if, however, the required rolling moment of 1.0 ...
2.0 Nm (without shaft sealing ring) cannot be achieved, the
bearing rolling moment must be corrected with a suitable spacer
ring !
Fig. 9
Insert pre-assembled input pinion, line up preheated bearing

inner ring, until it is in contact.
Fig. 10
Version "with" input flange (Fig.-No. 11 ..... No. 13):
Line up flange. (various flange designs – see

Fig.-No. 12 or. Fig.-No. 13 )
Fig. 11 Version → flange with hub spline:
Line up disc and tighten hexagon nut.

(in the case of self-securing versions – first use "old" hexagon
nuts which were removed during disassembly / use "new" ones
only after the assembly of the shaft sealing ring).
During tightening, repeatedly rotate input pinion in both

directions!
Tightening torque (M24x2) .................... MA = 450 Nm
Tightening torque (M27x1.5) ................. MA = 600 Nm
AS 2025/2035/2045
AS 2060
Fig. 12 (S) Counter support 5870 240 038
5871 693 012 2/4

Geschäftsbereich
und Achssysteme
Version → Standard flange:
Line up disc and tighten hexagon nut.
In the case of self-securing hexagon nuts, first use the "old"

hexagon nuts removed during disassembly
(repetition of the disassembly required for the subsequent
assembly of the shaft sealing ring).

directions!
Tightening torque (M24x2) ..................... MA = 450 Nm
Tightening torque (M27x1.5) .................. MA = 600 Nm
Fig. 13
Version "without" input flange (Fig-No. 14):
Tighten slotted nut.

directions!
Secure the slotted nut only after completed check of backlash
and contact pattern – see section 2.3.3./Page 2/38!
Tightening torque (M40x1.5) .................... MA = 500 Nm

Fig. 14 (S) Slotted nut wrench 5870 401 145
Check rolling moment !
Bearing rolling moment (without shaft sealing ring) 1.0 ... 2.0
Nm
Try to reach upper value.
If the required rolling moment should deviate, correct with a

suitable spacer ring (see Fig.-No. 9/Page 2.4) !
(S)Torque screw driver 5870 203 019

(S) Reduction ¼" to ½" 5870 656 056
(S) Reduction ½" to ¾" 5870 656 057
Fig. 15
Secure the slotted nut or hexagon nut only after completed

check of backlash and contact pattern – see section 2.3./Page
2/35 (various versions) !
5871 693 012 2/5

Geschäftsbereich
und Achssysteme
2.2 DIFFERENTIAL:
1 "I"
2.2.1 "DZ 250 or D 250":
(DZ = Multi-disc self-locking differential
D = Standard differential)
Legend to sketch:
I = Version D-250 (with differential rings)
II = Version DZ-250 (with disc packs)
1 = Differential rings (differential ring – at option)
2 = Disc packs (outer disc – at option)
2 "II"
Set axial clearance = 0.2 mm, per disc pack or differential ring

Fig. 16 (Fig.-No. 16 ... No. 20).
To achieve a correct measuring result for the disc clearance
(axial clearance), the components must first be mounted without
lubricant!
Place pressure disc (2), outer-(3, s = at option) and inner discs

(4) over the axle bevel gear as illustrated in the adjacent picture.
The coated surface of the pressure disc (2) shows towards the
outer disc (3).
Number and arrangement of the individual discs – see
representation in the respective spare parts list!
For version D 250, the outer and inner discs are substituted by
differential rings (per package – 1 unit) – also see perspective
Fig. 17
representation in the spare parts list !
Insert pre-assembled axle bevel gear into the differential case.
Fig. 18
Insert both differential bevel gears(1) and fix them with

differential axle (3).
Ensure radial installation position of the buffer disc as well as

installation position of the differential axle (fixing with clamping
pin)!
Fig. 19
5871 693 012 2/6

Geschäftsbereich
und Achssysteme
Check axial clearance of the individual disc pack!
Repeatedly rotate mounted axle bevel gear/with discs in both

directions (settling of the individual parts).
Axial clearance = 0.2 mm

In case of a deviation from the specified axial clearance, correct
with suitable outer discs or a differential ring!
Ensure identical thickness and arrangement of the second
disc pack or differential ring!
(S) Dial gage 5870 200 057

Fig. 20 (S) Magnetic stand 5870 200 055
After completed adjustment, disassemble parts again.
Oil all individual parts of the differential – use oil as per ZF list
of lubricants TE-ML 05 – and mount them again into the
differential case (Sketch-No. 16 ... Fig.-No.).
Fix differential axle with a clamping pin.
Drive in clamping pin only up to the axle centre (see arrow or

Sketch-No. 16)!
Fig. 21
Insert second disc pack – of identical arrangement and thickness.
Fig. 22
Mount clamping pins into the differential case half – observing

the assembly instructions – see Sketch-No. 24.
Fig. 23
5871 693 012 2/7

Geschäftsbereich
und Achssysteme
Assembly instructions:
X
Clamping pin(s) must be positioned with the slot showing into
the direction of force (arrow)!
For double clamping pins – displace slots by 180° towards each
other!
2
1 To sketch:
2 = Clamping pin
3 = Clamping pin (only for double clamping pin version)
Fig. 24 X = Direction of force
Press crown gear onto the differential case, until it is in contact..
Fig. 25
Fasten crown gear with cylindrical bolts.
Secure cylindrical bolts with Loctite (Type No. 243) !
Tightening torque (M10/10.9) ......... MA = 68 Nm
Fig. 26
Bring both tapered roller bearings into contact.
Fig. 27
5871 693 012 2/8

Geschäftsbereich
und Achssysteme
1 "I" 2.2.2 "DHL with DZ 250 or D 250":

A (DHL = Diff. hydr.-power shiftable = 100% lock)
B A = DHL-part
B = DZ- or D-part
I = Version D-250 → 1 = differential rings
II = Version DZ-250 → 2 = disc packs
The assembly of the DZ-part is largely analogous to the
description in section 2.2.1 Version DZ 250 (Page 2/6 ... Page
2/8) !
2 "II" The assembly of the DHL-part is largely analogous to the
description in section 2.2.4 Version DHL with DZ 400
Fig. 28 (Page 2/13 ... 2/21) !
Also see perspective representation in the respective spare parts
list
1
2.2.3 "DZ 400/500 or D 400/500":
"I" (DZ = Multi-disc self-locking differential,
D = Standard differential)
Legend to sketch:
I = Version D-400/500 (with differential rings)
"II" II = Version DZ-400/500 (with disc packs)
1 = Differential rings (differential ring – at option)
2 2 = Disc packs (outer discs – at option)
Fig. 29 To achieve a correct measuring result for the disc clearance
(axial clearance), the individual parts must first be mounted
without lubricant!
Mount clamping pins into the differential case half – observing

the assembly instructions – see Sketch-No. 31.
Fig. 30
X
The clamping pin(s) must be positioned with the slot showing
into the direction of force (arrow)!
other!
2
1 To sketch:
2 = Clamping pin
3 = Clamping pin (only for double clamping pin version)
Fig. 31 X = Direction of force
5871 693 012 2/9

Geschäftsbereich
und Achssysteme
Press crown gear via the clamping pins into the differential case
half.
Fig. 32
Set axial clearance = 0.20 mm of the two disc packs:
(Fig.-No. 33 ... Fig.-No. 38)
Place pressure disc (2), outer (3, s = at option) and inner discs
(4) over the axial bevel gear as illustrated in the adjacent picture.
3 The coated surface of the pressure disc (2) shows towards the
2
1 outer disc (3).
Equipment (number and arrangement of the individual discs) –
for other versions, if any – as illustrated in the respective spare

parts list!
4
For version D 400/500, the outer and inner discs are replaced by
representation in the parts list!
Fig. 33
Insert pre-assembled axle bevel gear into the differential case

half II.
Fig. 34
Line up differential bevel gears and buffer discs at the

differential spider and insert them into differential case half I.
Ensure radial installation position of the buffer disc!

The strap is showing vertically upwards (see arrow)!
Fig. 35
5871 693 012 2/10

Geschäftsbereich
und Achssysteme
Place differential case half II.
Ensure radial installation position – designation (ZF-No.) is, at

the same time, the radial position marking !
Fig. 36
Fix differential case halves with two cylindrical bolts for

measuring the axial clearance.
Fig. 37
Check axial clearance of the disc pack.
Repeatedly rotate mounted axle bevel gear/with discs into both

Axial clearance per disc pack = 0.20 mm

with suitable outer discs or differential ring.
(s = at option) !
(S) Magnetic holder 5870 200 055

Fig. 38 (S) Dial gage 5870 200 057
After completion of setting, separate again the two differential

case halves and disassemble the individual parts.
Setting and arrangement of the disc pack must not be changed.
Fig. 39
5871 693 012 2/11

Geschäftsbereich
und Achssysteme

Prior to the installation of all individual parts of the
differential, oil them (oil as per ZF list of lubricants TE-ML
05).
Insert pre-assembled axle bevel gear into differential case half I.
Fig. 40
Insert pre-assembled differential spider (with differential bevel

gears and buffer discs).
Ensure radial installation position of the buffer discs!
Strap is showing vertically upwards (see arrow)!
Fig. 41
Insert second axle bevel gear with the same setting and
arrangement into differential case half II.
Fig. 42
Place pre-assembled differential case half II.
Ensure radial installation position – designation (ZF-No. is, at

the same time, the marking of the radial position !
Fig. 43
5871 693 012 2/12

Geschäftsbereich
und Achssysteme
Fasten differential case halves with cylindrical bolts and

washers.
Tightening torque (M12x1.5/10.9) ...... MA = 122 Nm

Tightening torque (M12/12.9) .............. MA = 145 Nm
Fig. 44
Heat up bearing inner rings and line them up, until they are in
contact, reset after cooling down.
Fig. 45 2.2.4 "DHL with DZ 400/500 or D 400/500":

(DHL = Diff. hydr. power shiftable = 100% lock)
A = DHL-part
1 "I"
A B
B = DZ or D-part
I = Version D-400/500 → 1 = Differential rings
II = Version DZ-400/500 → 2 = Disc packs
Version – also see perspective representation in the respective
spare parts list.
To achieve a correct measuring result for the disc clearance

2 "II" without lubricant!
Fig. 46 Mount DZ or D -part ("B" –see Sketch-No. 46):

Set axial clearance = 0.20 mm of the two disc packs:
(Sketch-No. 46 ... No. 57)
3 Place pressure disc (2), outer (3, s = at option) and inner disc (4)
over the axle bevel gear, see adjacent picture.
2
outer disc (3).
Equipment (number and arrangement of the individual discs) as
4 represented in the respective spare parts list.
For version D 400/500, the outer and inner discs are substituted
by differential rings (1 package – 1 unit) – also see perspective
representation in the spare parts list!
Fig. 47
5871 693 012 2/13

Geschäftsbereich
und Achssysteme
Insert pre-assembled axle bevel gear into differential case half II.
Ensure correct installation position of the outer discs – position

driving lug in the radii of the fixing bores .
Fig. 48
Line up differential bevel gears and buffer discs at the

differential spider and insert them into differential case half II.
The straps of the buffer discs must be positioned in the recesses

of the differential case – see arrows!
Fig. 49
Place differential case half I onto the pre-assembled differential

case half II and fix with two cylindrical bolts (with washers) for
measuring the axial clearance.
Ensure correct installation position – designation (ZF-No.) is, at

the same time, the radial position marking for the two
differential case halves.
Fig. 50
Repeatedly rotate mounted axle bevel gear/with discs in both

Axial clearance per disc pack = 0.20 mm

with suitable outer discs (s = at option)!

Fig. 51 (S) Dial gage 5870 200 057
5871 693 012 2/14

Geschäftsbereich
und Achssysteme
After completion of setting, separate again the differential case

halves and disassemble individual parts again.
Setting and arrangement of the disc pack must not be changed.
Fig. 52

Prior to the assembly – oil all individual parts of the
differential (oil as per ZF list of lubricants TE-ML 05).
Place axle bevel gear (with pressure disc and disc pack –
maintain determined setting) into differential case half II.
Ensure correct installation position of the outer disc – position
driving lug in the radii of the fixing bores.
Fig. 53
Place complete differential spider.
The straps of the buffer discs must be positioned in the recesses

of the differential case - see arrow!
Fig. 54
Place axle bevel gear (with pressure disc and disc pack –
maintain determined setting) into the differential case halves.
Ensure correct installation of the outer discs – position driving

lug in the radii of the fixing bores.
Fig. 55
5871 693 012 2/15

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Place pre-assembled differential case half I.
Ensure correct installation position (ZF-No. is, at the same time,

radial position marking for the two differential case halves.
Fig. 56
Fasten differential case halves with cylindrical bolts and

washers.
Tightening torque (M12x1.5/10.9) ...... MA = 122 Nm

Fig. 57
Mount clamping pins into the blind hole of the crown gear –
observe the assembly instructions, see Sketch-No. 59.
Fig. 58
X
The clamping pin(s) (2) must be positioned with the slot
showing into the direction of force (arrow)!
other!
2
1
3 To sketch:
2 = Clamping pin
Fig. 59 3 = Clamping pin (only for double clamping pin version)
X = Direction of force
5871 693 012 2/16

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Press pre-assembled differential case – via the clamping pins –

into the crown gear, until they are in contact.
Fig. 60
Required only for version "DHL with DZ 250 or D 250"

4 (Sketch-No. 61):
5
Legend to sketch:
1 = Pressure disc 4 = Shim ring
2 = Snap ring 5 = Pressure ring (end shim)
3 3 = Snap ring X = Stamping reduction
X
2
1
Equipment (number and arrangement of the individual discs) as
represented in the respective spare parts list!
Mount pressure disc, snap rings and shim ring and check axial
Fig. 61 clearance of the disc pack = 0.20 mm.
Arrangement of the disc pack.
Legend to picture:
1 = End shim
(Ensure correct installation position / stamping reduction –
see Sketch-No. 61, Item 5).
2 = Inner discs
3 = Outer discs
4 = Pressure ring
of other versions, if any – as represented in the respective spare
parts list.
Fig. 62
Insert complete disc pack – also see Fig.-No. 62 – into the

differential case.
The recesses in the gearing of the end discs and outer discs must
correspond to the oil feed bores of the differential case – see
arrows!
Fig. 63
5871 693 012 2/17

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Setting instructions for DHL:

(DHL = Diff. hydr. power shiftable → 100% lock)
Ø 78 min. für DHL 250
Ø 74 min. für DHL 400/500 0.2 mm
Set measure "A" = 8.0 + , between differential cover
F 1 2 and pressure ring via outer discs (s = at option).
7
8 Maß II To that end, the disc pack "P1" must be axially pressurised
A
against surface "X" with F = 30 + 20 KN.
3 Maß I
P1
Legend to sketch:
4
X 1 = Differential cover
5
2 = Pressure ring
3 = Outer disc
6
4 = Inner disc
5 = End shim
7 = Cage
8 = Lever
Fig. 64
Set measure "A" = 8.0 +0.2 mm.
Determine measure I – observing the setting instructions (see

Sketch-No. 64) from mounting face/differential case up to the
pressure ring.
Measure I e.g. ........................................... 0.50 mm

(S) Load cell 5870700 004
Fig. 65
Determine measure II, from the land/lever to flange face/cover.
Measure II e.g.. ........................................ 7.60 mm
(S) Measuring ledge 5870 200 108

(S) Abutting block 5870 200 066
Fig. 66
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CALCULATION EXAMPLE:
Measure I e.g. ..................................... 0.50 mm

Measure II e.g. . ............................. + 7.60 mm
Result: Measure "A" 8.10 mm
If measure A = 8.0 +0.2 mm should not be reached, correct with

suitable outer disc(s)!
After completed setting – oil individual parts!
Position cage (arrow) and cover.
Fig. 67
Fasten cover with "new" securing bolts.
Securing bolts are permitted to be used only once!
Tightening torque (M10 x 1.25/10.9) ...... MA = 96 Nm
Fig. 68
Bring both bearing inner rings into contact.
Support bearing inner ring mounted first with a pressure piece!
DHL/DZ-250 / DHL-400
DHL-500
Fig. 69
Insert levers into the cage.
Ensure correct installation position – see Sketch-No. 64!
Fig. 70
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Insert snap ring into the annular groove of the cover.
Fig. 71
2 Insert clamping pins (ensure correct installation position –

position slots of the clamping pins in axial direction and
displaced by 180° towards each other – see arrow)!
Line up plate spring (ensure correct installation position – also
see Sketch-No. 46, Page 2/13) and centering plate.
Legend to picture:
1 = Sliding sleeve
1 2 = Clamping pins
3 = Plate springs
4 3 4 = Centering plate
Fig. 72
Displace centering plate by at least ¼ rotation (mounting recess

to clamping pin ) see arrows!
Fig. 73
Check position of the levers (see Fig.-No. 70)!
Insert pre-assembled sliding sleeve, until it is axially fixed (snap

ring) – place clamping pin into the slot of the cover – see arrows.
Fig. 74
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Line up axial roller ring.
Fig. 75
Oil both four-lip sealing rings and insert them into the annular
groove of the axle casing (see arrows).
Fig. 76
Insert piston (oil sealing faces), until it is in contact.
Fig. 77
5871 693 012 2/21

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und Achssysteme
2.2.5 "DHL with DZ 750 or D 750:

1 "I"
A (DHL = Diff. hydr. power shiftable = 100% lock)
B A = DHL-part
B = DZ or D-part
I = Version D-750 → 1 = Differential rings
II = Version DZ-750 → 2 = Disc packs
For the different version – also see perspective representations in
the respective spare parts list.
2 "II" To achieve a correct measuring result for the disc clearance
without lubricant!
Fig. 78
Set axial clearance = 0.00 ... 0.15 mm of the disc pack

(Sketch-No. 78 ... No. 92)
3 Place pressure disc (2), outer (3, s = at option) and inner discs
(4) over the axle bevel gear as represented in the adjacent
2 picture.
1
The coated surfaces of the pressure disc (2) shows towards the
outer disc (3).
4 Equipment (number and arrangement of the individual discs) –of
other versions, if any- as represented in the respective spare parts
list!
Fig. 79 differential rings (per package – 1 unit) – also see perspective
representation in the spare parts list.
Place pre-assembled axle bevel gear into the differential case.
Ensure correct installation position of the outer discs – position

Fig. 80
Legend to Fig.-No. 81 ... No. 83:
2 Differential spider – individual parts:

1 = Differential axle (one-piece design)
2 = Differential axle (split design)
3 = Differential bevel gear (4x)
2 4 = Buffer disc (4x)
1
3
4
Fig. 81
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Introduce one-piece differential axle (1) into the bore without

clamping pin fixing bore and line up two differential bevel gears
(3) with buffer discs (4).
Insert buffer discs with the straps showing downwards – see

arrow - and placed in the recess.
Fig. 82
Mount split differential axle (2) with differential bevel gears (3)
and buffer discs (4).
Insert buffer discs with straps showing downwards – see arrow –

and placed in the recess.
Ensure correct installation position of the differential axle halves

– clamping pin fixing bores of differential axle and differential
case!
Fig. 83
Repeatedly rotate mounted axle bevel gear with discs into both
Fig. 84
Axial clearance of the disc pack = 0.00 ... 0.15 mm
In case of a deviation from the specified axial clearance,

correct with suitable outer (s = at option)!
After the completion of setting – maintain disc setting and

arrangement – disassemble the parts again, oil and install them
again – oil as per ZF list of lubricants TE-ML 05!

Fig. 85 (S) Dial gage 5870 200 057
5871 693 012 2/23

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Fix both differential axle halves with clamping pins.
Insert clamping pin – the slot showing upwards towards the

differential case centre
Fig. 86
Set axial clearance = 0.00 ... 0.15 mm of the disc pack:
(Fig.-No. 87 ... No. 90 – also see Sketch-No. 78)
Place pressure disc (2), outer-(3, s = at option) and inner discs

3 (4)over the axle bevel gear as represented in the adjacent picture.
1
outer disc (3).
of other versions, if any – as per representation in the respective
spare parts list!
4
representation in the spare parts list!!
Fig. 87
Place pre-assembled axle bevel gear into the differential case!
Ensure correct installation position of the outer discs –position

Fig. 88
Repeatedly rotate mounted axle bevel gear in both directions

(settling of the individual parts).
Fig. 89
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Axial clearance of the disc pack = 0.00 ... 0.15 mm
Keep disc pack with axle bevel gear in contact and determine
axial clearance of the disc pack from the face/inner disc to
contact face differential case/pressure ring.

with suitable outer discs (s = at option)!
Fig. 90
Oil individual parts – maintaining setting and arrangement – of

the disc pack.
(Use oil as per ZF list of lubricants TE-ML 05).
Place pressure ring.
Fig. 91
Fasten pressure ring with hexagon bolts.
Tightening torque (M 8/10.9) ............... MA = 34 Nm
Fig. 92
Position cylindrical pins – with grease (assembly aid).
Fig. 93
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Arrangement of the disc pack.

2
Legend to picture:
1 = Inner discs
2 = Outer discs (s = at option)
3 3 = Pressure ring

1 of other versions, if any – as represented in the respective spare
parts list!
Fig. 94
Insert complete disc pack – also see Fig.-No. 94 – into the

differential case.
Line up outer discs (with recesses - positioned in the inserted

cylindrical pins).
Fig. 95
Setting instructions for DHL:

(DHL = Diff. hydr. power shiftable → 100% lock)
Ø 74 min. für DHL 750 0.2 mm
Set measure "A" = 8.0 + , between differential cover
6
F 1 2 and pressure ring via outer discs (s = at option).
Maß II To that end, the disc pack "P1" must be axially pressurised
7
against the surface "X"
A - with F = 30 + 20 KN.
3 Maß I (S) Load cell 5870 700 004
P1
4
X 5
Legend to sketch:
1 = Differential cover
2 = Pressure ring
3 = Outer disc
4 = Inner disc
6 = Cage
7 = Lever
Fig. 96
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Set measure "A" = 8.0 +0.2 mm.
Determine measure I – observing the setting instructions (see

Sketch-No. 96) from flange face/differential case to pressure
ring.
Measure I e.g. ........................................... 6.40 mm

(S) Load cell 5870 700 004
Fig. 97
Determine measure II, from land/lever to flange face/cover
Measure II e.g. ........................................ 1.70 mm

Fig. 98
Measure I e.g. ..................................... 6..0 mm

Measure II e.g. ..................................... + 1.70 mm
Result: Measure "A" 8.10 mm
If measure A = 8.0 +0.2 mm should not be reached, correct with

suitable outer discs!
Mount snap ring (see arrow) into the groove of the disc carrier..
Fig. 99
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und Achssysteme
Withdraw disc pack from the differential case.
Insert pre-assembled disc carrier, observe installation position –

see picture.
Fig. 100
Oil individual parts of the disc pack.
Insert complete disc pack again – as set.
Check position of the cylindrical pins.

Position outer disc – with recesses – in the inserted cylindrical
pins!
Fig. 101
Place pressure spring and piston into the cover.
Fig. 102
Fix piston with retaining ring.
Fig. 103
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Line up support shim (s = constant).
Fig. 104
Insert cage.
Fig. 105
Position levers with grease (assembly aid) in the cage.
Ensure correct installation position of the levers – also see

Sketch-No. 78, Page 2/22!
Fig. 106
Place pre-assembled cover.
Fig. 107
5871 693 012 2/29

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Screw in two adjusting bolts and line up or press in heated up

crown gear, until it is in contact.
(S) Adjusting bolts (M14 x 1.5) 5870 204 025
Fig. 108
Fasten cover with "new" retaining bolts.
The retaining bolts are permitted to be used only once!
Tightening torque (M14 x 1.5/12.9) ...... MA = 280 Nm
Fig. 109
Press bearing inner ring, until it is in contact.
Fig. 110
Press in bearing inner ring on the crown gear side, until it is in

contact.
Use suitable support for pre-assembled bearing ring, roller

bearing cage – risk of damaging!
Fig. 111
5871 693 012 2/30

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Oil both four-lip sealing rings and insert them into the annular
grooves of the axle casing Part II (see arrows).
Fig. 112
Oil piston sealing faces, insert them, until they are in contact.
Fig. 113
2.2.6 Set backlash of the crown gear set

and bearing rolling moment of the
differential bearing
(Fig.-No. 114 ... No. 122)
Backlash:
AS 2025/2035 = 0.7 . .. 0.22 mm
AS 2045/2055 = 0.10 ... 0.25 mm
AS 2060/2075 = 0.10 ... 0.28 mm
Bearing rolling moment:

All differential types = 1 ... 4 Nm
Bring axle casing/Part I into vertical position!

Insert adjusting spacer (backlash) into the bore of the axle
casing/Part I and introduce bearing outer ring, until it is in
contact.
It is recommended to use the adjusting spacer(s) found during

disassembly – also see disassembly instruction Page 1/19, Fig.-
No. 73!
Decisive for the adjusting spacer(s) to be used, however, is
the required backlash!
Fig. 114
5871 693 012 2/31

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Wet some tooth flanks of the crown gear with touching-up ink
(contact pattern).
Fig. 115
Mount pre-assembled differential into the axle casing/Part I.
Fig. 116
Only for differential versions "with" DHL - (Fig.-No. 117):
Fig. 117
Position bearing outer ring.
Repeatedly rotate differential and bearing outer ring in both

directions – settling of the rollers!
Fig. 118
5871 693 012 2/32

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Determine measure "I" from the flange face of the axle
casing/Part II to the bearing contact.
Measure "I" e.g.. ........................................ 30.15 mm

Fig. 119
The correct positioning of bearing outer ring and differential

is absolutely necessary for the following measurement!
Determine measure "II", from the flange face of the axle

casing/Part I to the front face/bearing outer ring.
Measure "II" e.g.. ................................. 28,20 mm
Make measurements at several points and determine average

value!
Fig. 120 CALCULATION EXAMPLE:
Measure "I" e.g. .................................. 30.15 mm

Measure "II" e.g. ................................ -28.20 mm
Difference .......................................... 1.95 mm
required bearing preload...................... + 0.10 mm
Result → Adjusting spacer "S" = 2.05 mm
For version with the bearing contact surface being in the

plus area (above the flange face axle casing/Part II – Fig.-No.
119), the calculation example must be accordingly adapted!
A bearing preload of 0.10 mm results – on an empirical basis –

in a bearing rolling moment of 1 ... 4 Nm!
Insert determined adjusting spacer(s) e.g. s=2.05 mm into the

bearing bore of the axle casing/Part II and reset bearing outer
ring, until it is in contact.
Fig. 121
5871 693 012 2/33

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Mount two adjusting screws, place axle casing/Part II (without

O-ring) onto axle casing/Part I and temporarily fasten with
hexagon bolts (4/5 units).
(S) Adjusting bolts (M16) 5870 204 023

(S) Adjusting bolts (M18) 5870 204 026
Fig. 122
2.2.7 Check DHL (100% lock) for tightness:
Build up a pressure of p = 20 bar using a HP-pump – breathing
the pressure compartment.
Close shut-off valve-
During a test time of 5 minutes, no measurable pressure drop
must occur.
(S) HP-pump 5870 287 007
Test media (engine oils):

SAE 10 W, MIL-L 2104, MIL-L 46152
API-CC, CD, SC, SD,SE
ATF-oils
Fig. 123 TYPE A Suffic A, Dexron of II D
2.2.8 Check backlash and contact pattern of the

crown gear set:
Repeatedly roll input pinion in both directions over the crown
gear.
Fig. 124
Introduce dial gage, through the oil draining bore, rectangularly

to a tooth flank of the crown gear and check backlash.
Backlash:
AS 2025/2035 = 0.7 .. . 0.22 mm
AS 2045/2055 = 0.0 ... 0.25 mm
AS 2060/2075 = 0.10 ... 0.28 mm
If the specified backlash should deviate, it must be corrected

with a suitable adjusting spacer (see Fig.-No. 114, Page 2/31)!
Fig. 125 (S) Dial gage 5870 200 057

(S) Magnetic stand 5870 200 055
5871 693 012 2/34

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Disassemble differential again.
Compare contact pattern (see arrow) with contact pattern

examples on Page 0/6 ...0/07.
If a major deviation of the contact pattern should be found, a

measuring mistake occurred when determining the adjusting
spacer (see Fig.-No. 5, Page 2/3) which must absolutely be
corrected!
Fig. 126
2.3 Mounting the drive flange and shaft sealing

ring or securing the input pinion nut:
1
2.3.1 Version "A":
(Sketch-No. 127 ... No. 132)
2 5
Legend to sketch:
3 6
1 = Axle casing 2 = Shaft sealing ring
4 7 3 = Screening plate 4 = Input flange
5 = Input pinion 6 = Disc
Fig. 127 7 = Locking nut
Insert shaft sealing ring – specified installation position

(depending on the version) as per Sketch-No. 129 or 130.
Contact surface (outer diameter) of the shaft sealing ring to be

treated as follows:
- if rubberised, to be wetted with spirit (assembly aid)
- if of metal, to be provided with sealant (Loctite No. 574)
Grease shaft sealing ring in the area of the sealing- and dust lip!
(Grease "PETAMO" ZF-ordering-No. 0671 190 099)
Ensure plane installation position of the shaft sealing ring – use
suitable support!
Fig. 128
Version "I" – Installation measure shaft sealing ring X = 15.1

+0.2
mm
Shaft sealing ring 50x80x10/10.5

(S) Support 5870 048 158
Shaft sealing ring 45x70x10

(S) Support 5870 048 173
X
Fig. 129
5871 693 012 2/35

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Version "II" – Installation measure shaft sealing ring X = 17.1

±0.2
mm
Shaft sealing ring 65x90x10/14.5

(S) Support 5870 048 234
X
Fig. 130
Disassemble flange.
Press screening plate onto flange.
The screening plate must not be deformed during the assembly –

use suitable pressure piece!
Fig. 131
Line up flange and disc and finally fasten with hexagon nut
- for standard version – insert hexagon nut with
(Loctite No. 574)

- for version "self-securing", use "new" retaining nut.
Tightening torque (M24x2) ................... MA = 450 Nm

Tightening torque (M27x1.5) ................ MA = 600 Nm
Fig. 132
2.3.2 Version "B":

(Sketch-No. 133 ... No. 138)
Legend to sketch:
1
2 5 1 = Axle casing 2 = Shaft sealing ring
3 = Screening plate 4 = Input flange
3 5 = Input pinion 6 = Disc
6
7 = Locking nut
4 7
Fig. 133
5871 693 012 2/36

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und Achssysteme
Insert shaft sealing ring – required installation position

(depending on the version) see Sketch-No. 135 or No. 136.

treated as follows:

suitable support!
Fig. 134
–
Version "I" – Installation measure shaft sealing ring X = 13.5
0.2.
mm
Combination sealing ring 48x80x10/15.5

(S) Support 5870 048 214
Fig. 135
Version "II" – Installation measures shaft sealing ring X = 2.0

+0.5
mm
X (S) Shaft sealing ring 60x90x10/14.5

(S) Support 5870 048 120
Fig. 136
Disassemble flange.
Press screening plate or, for version with combination sealing

ring (screening- and shaft sealing ring), the screening ring, onto
the flange, until it is in contact.
During the assembly, the screening plate or screening ring must

not be deformed – use suitable pressure piece!
Fig. 137
5871 693 012 2/37

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und Achssysteme
Line up flange and disc and finally fasten with hexagon nut
- for standard version – insert hexagon nut with
(Loctite No. 574)
- for version "self-securing", use "new" retaining nut.

Tightening torque (M27x1.5) ................ MA = 600 Nm
AS - 2025/2035/2045
AS – 2060
Fig. 138
2.3.3 Version "C":

2 (Sketch-No. 139 .... Fig.-No. 147)
1
Legend to sketch:
1 = Axle casing
2 = Pinion
3 = Slotted nut
4 = O-ring
5 = Bush
6 = Retaining ring
3 7 = Retaining ring
6
8 = Combination sealing ring (screening- + shaft sealing ring)
9 4 8 10 = Bush
11 11 = Protection sleeve
10
5 7
Fig. 139
Secure slotted nut (peening in the securing groove/pinion).
(S) Slotted nut wrench 5870 401 145

(S) Splined bush 5870 512 013
Fig. 140
5871 693 012 2/38

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und Achssysteme
Mount inner retaining ring (bush fixing).
Oil O-ring and insert it into the annular groove of the pinion (see
arrow).
Fig. 141
Legend to Sketch-No. 142 ... Fig.-No. 147:
1 3 1 = Bush
2 = Combination sealing ring
4 2/a (2/a shaft sealing ring + 2/b screening ring/bush)
3 = Bush
4 = O-ring
I
II I = Installation measure/shaft sealing ring → 6 + 0.5 mm
2/b II = Installation measure/screening ring → 5.6 + 0.2 mm
(S) Support 5870 048 248

Fig. 142 (S) Support 5870 048 249
Oil O-ring (4) and insert it into the annular groove of the bush(1)
(see arrow).
Mount shaft sealing ring 2/a) into the bush (1) considering the
installation measure I = 6 + 0,.5 mm.
Ensure correct installation position – also see Sketch-No. 142!

treated as follows:
Fig. 143
suitable support!
(S) Support 5870 048 248
Insert pre-assembled bush, until it is in contact.
Fig. 144
5871 693 012 2/39

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und Achssysteme
Mount screening ring (2/b) onto the bush (3), considering the
installation measure II = 5.6 + 0.2 mm – also see Sketch-No. 142!
The screening ring must not be deformed during the assembly –
use specified support.
(S) Support 5870 048 249
Fig. 145
Insert pre-assembled bush, until it is in contact.
Fig. 146
Fix bush with retaining ring.
Mounting of the protection sleeve – see section 2.6.4

Self-aligning bearing – version "D" /Page 2/77!
Fig. 147
Insert differential again.
Fig. 148
5871 693 012 2/40

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Only for differential versions "with" DHL - (Fig.-No. 149):
Fig. 149
Oil O-ring (see arrow) and insert it into the annular groove of the
axle casing/Part II..
Fig. 150
Position axle casing/Part II again – fasten it with hexagon bolts

or hexagon nuts (stud bolts) or cylindrical bolts as well as
washers.
Tightening torque (M14/10.9) ............... MA = 185 Nm

Ensure correct installation position of the two axle casing halves
(fork head position)!
a
b For version "with "stud bolts" – position of the individual stud
bolts according to arrows "a" and "b".
Fig. 151 During the combination of the axle casing, mount hexagon nut
(see arrow "a").
Insert articulated shaft into the gearing of the differential and

position complete output at the axle.
Observe shaft sealing ring in the axle casing– risk of damaging!

Further required working steps (installation of bearing bolt
and track rod) may be taken by excerpts from the
description of the overall assembly (section 2.2.4, joint
housing, Page 2/45 and section 2.5, steering, Page 2/72 and
2/73)!
Fig. 152
5871 693 012 2/41

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2.4 OUTPUT:
2.4.1 Pre-assemble axle casing:

Mount bush, depending on the version – considering the correct
installation position / see Sketches-No. 153, No. 154 and No.
155, in a flush manner.
AS - 2025/2035/2045/2055/2060
(S) Support 5870 048 156
AS – 2075
Fig. 153 (S) support 5870 055 113
Legend to sketch:
1 = Axle casing
2 2 = Bush
3 = Oil groove
3 X = Oil compartment side
X Installation position of the bush – oil groove outlet
in '6 o' clock' position
(related to the axle mounted in the vehicle)
1
Fig. 154
Legend to sketch:
1
1 = Axle casing
2 2 = Bush
X = Installation position of the bush – lining in 'noon' clock

X position
(related to axle mounted in the vehicle)
Fig. 155
Legend to sketch:
1 1 = Axle casing
2 = Bush
2
X = Installation position of the bush – linking in 'noon' clock
position
X (related to axle mounted in the vehicle)
Fig. 156
5871 693 012 2/42

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und Achssysteme
Insert shaft sealing ring in a flush manner into the bore of the
axle casing, the sealing lip showing towards the oil

compartment.

treated as follows:
- if of metal, to be provided with sealant ('Spezialtyp 1108', ZF-

ordering-No. 0666 790 047)
Fig. 157 suitable support!
AS - 2025/2035/2045/2055/2060
(S) Support 5870 048 156
6 with support 5870 048 157
5 AS – 2075
(S) Support 5870 055 113
3
2.4.1.1 Only for version "with" angle sensor system -
mount foot plate of the angle sensor and plug
4 as well as plug and socket connection:
(Sketch-No. 158 ... Fig.-No. 165)
3/d 3/b
3/a 2 3/c
Legend to sketch: 3/a Foot plate
Fig. 158 1 = Axle casing 3/b Conn. cable
2 = Locking cover 3/c O-ring
3 = Angle sensor with 3/d O-ring
4 = Roller bearing(bearing outer
ring)
5 = Bearing bolt
6 = Joint housing
Insert cover with sealant "Spezialtyp 1108"

ZF-ordering-No. 0666 790 047.
Fig. 159
Introduce connecting cable (3/b) into the cable duct of the axle
3/a
3/d casing.
Grease O-rings (3/c + 3/d) and insert them into the annular
3/c
grooves of the foot plate (3/a).
X Insert pre-assembled foot plate – with stop pin positioned in the
stop bore (see arrow X) of the axle casing.
3/b
Fig. 160
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Only for angle sensor system – version "with" tube:

(Fig.-No. 161 and Fig.-No.162)
Insert tube, line up connecting cable.
Fig. 161
Insert O-ring..
Fig. 162
Pre-assemble plug (with connecting cable):

(Fig.-No. 163)
1
Insert seal (2) (installed only for version - with cable duct) into
the plug (1).
For version "with" tube (see Fig.-No. 161), no seal (2) is
3 installed.
2
Line O-ring (3), cover (4, ensure correct installation position),
O-ring (5) onto plug (1) and mount retaining ring.
6 4
5
Fig. 163
Connect pre-assembled plug with the connecting cable of the

angle sensor (foot plate).
Provide contact surface of cover/axle casing with anti-corrosive

"Weicon Anti-Seize" ZF-ordering-No. 0671 196 001!
Fig. 164
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Fasten plug with hexagon bolts.
Fig. 165
Insert both bearing outer rings into the swivel bearing of the axle
casing.
Bearing M86610
(S) Support 5870 058 047
Bearing HM88610
(S) Support 5870 058 062
Fig. 166
2.4.2 Joint housing:

Drive in ball bearing, until it is in contact.
Fig. 167
Fix ball bearing with retaining ring.
Fig. 168
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Legend to picture:
1/a = Shaft sealing ring
1/b 1/b = Screening plate
Withdraw screening plate for inserting the shaft sealing ring.
1/a
Fig. 169
Legend to sketch:
6 1 = Shaft sealing ring 5 = Joint housing
Z
2 = Retaining ring 6 = Double articulated shaft
3 = Ball bearing 7 = Snap ring
4 = Retaining ring 8 = Sun gear shaft
1 Detail "Z": AS - 2025/2035/2045/2055
5 Install. measure → X = 2. + 0.2
2 mm
4 X
AS - 2060/2075
3 7 Install. measure → X = 4.0 + 0.2
8
mm
Fig. 170
Provide contact surface shaft sealing ring/joint housing with

sealant ('Spezialtyp 1108', ZF-ordering-No. 0666 790 047) and
insert shaft sealing ring, considering the installation measure X -
see Sketch-No. 170/Detail Z .

suitable supports!
AS - 2025/2035
(S) Support 5870 048 155
AS - 2045/2055
(S) Support 5870 048 155
Fig. 171 with support 5870 048 172
AS - 2060/2075
(S) Support 5870 048 205
Insert screening plate.
Fig. 172
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und Achssysteme
Line up screening plate and heated up bush on the double

articulated shaft and bring them into contact using a pressure
piece/tube – also see Sketch-No.174.
Ensure correct installation position of screening plate and bush –

see Sketch-No. 174!
AS - 2025/2035/2045/2055/2060
AS – 2075
(S) Support 5870 506 145
Fig. 173
Legend to Fig.-No. 173 and Sketch-No. 174:

2 1
1 = Double articulated shaft
3 2 = Screening plate
3 = Bush
Fig. 174
Directly prior to the assembly, wet contact surface shaft sealing

ring/double articulated shaft with spirit (assembly aid).and line
up pre-assembled double articulated shaft in the joint housing.
Fig. 175
Draw double articulated shaft into the joint housing, until it is in

contact.
Position internal extractor in the groove of the double articulated

shaft!

Fig. 176
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und Achssysteme
Insert retaining ring (sun gear shaft fixing) into the annular
groove (arrow)
Fig. 177
Position joint housing at the axle casing , introduce double

articulated shaft into the axle casing, until the gearing at the
articulated shaft is accepted in the differential (axle bevel gear)!
Fig. 178 2.4.3 Swivel bearing:

Shaft sealing ring - Version "A" (see Sketch-No. 180)
Prior to inserting it, provide contact surface – shaft sealing

ring/bearing bolt (metal) with sealant "Spezialtyp 1108"
ZF Ordering-No.: 0666 790 047".
Combination sealing ring – Version "B" (see Sketch-No. 180)
Internal diameter with sprayed-on sealing varnish (green).
Combination sealing ring to be mounted without sealant!
Press – do not drive, risk of damaging – shaft sealing ring or
combination sealing ring - see Sketch-No. 180 – onto bearing
bolt, considering the installation measure.
Installation measure:
Fig. 179 Shaft sealing ring (Version "A") = 0.4 + 0.1 mm
Combination sealing ring (Version "B") = 0. mm (flush)
The use of the specified support ensures an exact and correct
0,4+ 0,1 mm 0,0 mm assembly!
AS 2025/2035/2045 → Shaft seal. ring - Combin. seal. ring

(S) Support 5870 048 154 5870 048 251
AS 2055/2060/2075 → Shaft seal. ring - Combin. seal. ring

"A" "B" (S) Support 5870 048 204 5870 048 252
Version Version Legend to sketch:
1 = Bearing bolt
Fig. 180 3 = Combination sealing ring
5871 693 012 2/48

Geschäftsbereich
und Achssysteme
Line up bearing inner ring(roller bearing)and press it onto the

bearing bolt, until it is in contact.
Provide collar of the bearing bolt (see arrow) with anti-corrosive

"Weicon Anti-Seize" ZF-Ordering-No. 0671 196 001!
Fig. 181 Only for version "without" lubricating nipple:

Provide roller bearing/bearing bolt with long-cycle lubricant
(Life-time grease packing, e.g. Glisando 283 EP 2 LF) – ZF-
Ordering-No. 0671 190 079).
Only for version "with" lubrication nipple:

Mount bearing bolt with the lubrication nipple showing towards
the axle centre-
Fix joint housing with pre-assembled bearing bolt.

(see Fig.-No. 182 .... No. 184).
Directly prior to the assembly of the bearing bolt, wet rubberised

area of the shaft sealing ring (external shell) with spirit –
assembly aid!
Fig. 182
At the upper bearing bolt, insert shim (s = 0.80 mm, empirical

value) for setting the bearing roller moment
For version "with" dual sensing system – ensure correct

installation position of the respective bearing bolt –
recesses/control edge must show towards the assembly bores of
the dual sensors.
Fig. 183
Only for version "with" angle sensor system:
(Fig.-No. 184)
Ensure correct installation position of the bearing bolt – the

fixing bore (arrow) for the sensor cover must show towards the
axle centre!
Only one bearing bolt (with sensor) is installed at the axle

casing (rest = standard version) !
Installation position of the bearing bolt with sensor
equipment (axle casing in top position) – also see section
2.4.1.1, Page 2/43!
Sensor assembly – see section 2.4.7.1/ Page 2/61!
Fig. 184
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Fasten bearing bolt with hexagon bolts.
Tightening torque (M 12/10.9) MA = 117 Nm

Tightening torque (M 14/10.9) MA = 185 Nm
Fig. 185 Check rolling moment of the self-aligning bearing.

AS 2025/2035/2045
Bearing rolling moment .................. 18 - 20 Nm
(with installed shaft sealing ring)
AS 2055/2060/2075
Bearing rolling moment .................. 23 - 30 Nm
(with installed shaft sealing ring)
Try to reach the upper value for the bearing rolling moment!
In case of deviation from the specified rolling moment, correct
with a suitable adjusting spacer (Fig.-No. 183)!
(S) Wrench 5870 656 004

(S) Torque wrench 5870 203 033
Fig. 186
2.4.4 Hub:
Mount wheel bolt – ensure correct installation position!
(S) Wheel bolt puller – basic tool 5870 610 010

(S) Insert (M18x1.5) 5870 610 004
(S) Insert (M20x1.5) 5870 610 003
(S) Insert (M22x1.5) 5870 610 002
(S) Insert (¾ - 16 UNF) 5870 610 005
Fig. 187
Press in both bearing outer rings, until they are in contact.
Fig. 188
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und Achssysteme
Wet contact surface shaft sealing ring with sealant ('Spezialtyp

1108', ZF-Ordering-No. 0666 790 047) and press shaft sealing
ring flush into the hub, the lettering "LUFT SEIT/OUT SIDE"
showing outwards (towards the top).
The use of the specified support ensures an exact and correct

assembly!
(S) Support 5870 051 035
Fig. 189
Heat up bearing inner ring and line it up, until it is in contact.
Fig. 190
Directly prior to the assembly of the hub, wet contact surface

shaft sealing ring/joint housing with spirit (assembly aid)!
Line up hub and fix it with heated up bearing inner ring.
Fig. 191
2.4.5 Internal gear / Multi-disc brake:
2.4.5.1 Standard version ("without" multi-disc brake):

(Fig.-No. 192 ... No. 194)
Line up internal gear.
Ensure correct installation position! Mount internal gear, with

the oil passage bores downwards (related to the axle mounted in
the vehicle) (also see Fig.-No. 193)!
Fig. 192
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und Achssysteme
Fasten internal gear.
Secure bolts with (Loctite No. 243)!

During tightening, repeatedly rotate the hub in both directions –
settling of the rollers.
Tightening torque (M 10/12.9) .................. MA = 68 Nm
Fig. 193
Introduce sun gear shaft, until retaining ring (inserted in the

double articulated shaft - see Fig.-No. 177, Page 2/48) is
engaged in the fixing groove.
Fig. 194
2.4.5.2 Version "with" multi-disc brake:

(Fig.-No. 195 ... No. 216)
Heat up both supporting rings in an oil bath and insert them into
the annular grooves (see arrows) of the piston, then, mount both
grooved rings.
Ensure correct installation position – see Sketch-No. 196!
Fig. 195
3 2 Legend to sketch:
X 1 1 = Piston
2 3
2 = Supporting ring
3 = Slotted ring
x = Pressure compartment
Fig. 196
5871 693 012 2/52

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Insert assembly ring (S) into the internal gear.
AS 2035
(S) Assembly ring 5870 347 018
AS 2045
AS 2060
Fig. 197
Oil sliding surface of the assembly ring or the supporting- and

grooved rings (SAE 10-W oil) .
After cooling down of the supporting rings, insert piston into the
assembly ring.
Ensure radial position of the tension spring passage bore!
Fig. 198
Carefully bring piston into contact using a manual press.

Then, remove assembly ring.
Fig. 199
Position spring clip with all tension springs (introduce into the
bores) at the internal gear.
Tension springs must always be renewed by sets (per input).
Fig. 200
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und Achssysteme
Fix internal gear in a vice and suspend all tension springs in the
front spring clip.
(S) Spring hook 5870 281 029
Fig. 201
Glue O-ring (see arrow 1) with grease in the recess of the

internal gear.
Only for the assembly of new parts:

Close opening (see arrow 2) of the oil feed bore with locking
plug!
1
(S) Lever-type riveting tongs 5870 320 016

2
Fig. 202
Bring pre-assembled internal gear into position at the axle.
Upon lining up, the exact correspondence of the oil feed bores
(joint housing/internal gear) must be ensured!
Fig. 203
Fasten internal gear
Secure bolts with sealant (Loctite No. 243)!
Fig. 204
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Insert sun gear shaft into the double articulated shaft, until the
retaining ring (inserted into double articulated shaft - see Fig.-
No. 177, Page 2/48) is engaged in the groove (see arrow).
Fig. 205
Mount retaining ring into the rear annular groove of the sun gear
shaft.
Fig. 206
Mount retaining ring (oil stop) into the groove of the clutch disc
carrier.
Fig. 207
Line up clutch disc carrier on the sun gear shaft, until it is in

contact.
Fig. 208
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und Achssysteme
Fix clutch disc carrier with retaining ring.
Fig. 209
Legend to sketch:
6 1 = Internal gear
1 5 2 = Piston
2
7
34
3 = Outer discs (s=at option)
4 = Inner discs } number = depend.
on version
5 = End shim
8 6 = Retaining ring
7 = Sun gear shaft
8 = Clutch disc carrier
Fig. 210
Starting with an outer disc, alternatingly line up discs in the

internal gear.
The number of discs (and their arrangement – for deviating

versions) must be taken from the respective spare parts list!
Fig. 211
Line up end shim – ensuring the correct installation position -

(see Sketch-No. 210) and fix with retaining ring.
(S) Collet 5870 900 021
Fig. 212
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und Achssysteme
2.4.5.2.1 Setting of the piston stroke:

(Sketch-No. 213 .... Sketch-No. 214)
"I" Required piston stroke (when using new discs)):

Version 3 outer /2 inner discs = 1.5 ... 1.9 mm
F Version 4 outer-/3 inner discs = 2.25 ... 2.85 mm
Bring piston, disc pack and end shim into contact with the
internal gear base (see arrow F).
Determine measure "I", from front face/internal gear to front

face/end shim.
Fig. 213
Measure"I" e.g.. ................................. 67.95 mm
Bring end shim and retaining ring into contact.

(see arrow F).
"II" F Determine measure "II", from front face/internal gear to front
face/end shim.
Measure"II" e.g. ................................. 66.30 mm
Measure "I" e.g. ................................ 67.5 mm

Fig. 214
Measure "II" e.g.. .............................. - 66.30 mm
Difference piston stroke .................. = 1.65 mm
If the required piston stroke (depending on the disc equipment –

see information above) is not reached, correct with a suitable
outer disc
After completed setting of the piston stroke, disassemble discs
again, oil them and install them again – maintaining their setting.
Oil as per ZF-list of lubricants TE-ML 05!

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2.4.5.2.2 Check hydr. brake system for tightness:

Mount pressure connection and breather.
Fig. 215

Prior to starting the check, vent hydr. brake system, then
repeatedly operate it (at least 10 times)!
High-pressure test:
Build up test pressure p = 150 bar and interrupt connection to the
HP-pump via shut-off valve.
During a test time of 5 minutes, a pressure drop of max. 2% (p =
117 bar) is admissible!
Low-pressure test:
Reduce test pressure to p = 5 bar and close again shut-off valve.
At a test time of 5 minutes, a pressure drop is not admissible.
Fig. 216
Test media:
Engine oils SAE 10-W corresponding to,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-oils Type A, Suffic A Dexron
of II D.
(S) HP-pump 5870 287 007

(S) Mini-measuring coupling (M 12x1.5) 5870 950 101
5871 693 012 2/58

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und Achssysteme
2.4.6 Planet carrier:
4 2.4.6.1 Version "A"

3 Planet gear support with cylindrical roller
bearing:
(Fig.-No. 215 ... No. 220)
3
Pre-assemble planet gear (version "without" supporting rings).
(Version as per respective spare parts list)
2 1 Legend to picture:
1 = Planet gear
2 = Bearing inner ring (with cylindrical rollers
Fig. 217
3 = Angle ring
4 = Plastic ring/assembly aid

Observe installation position of the angle rings – stepped contour
must always show outwards!
Pre-assemble planet gear (version "with" planet gear).

(Version as per respective spare parts list)
4
1 1 = Planet gear
2 = Bearing inner ring (with cylindrical rollers)
2 3 = Supporting ring
3 4 = Angle ring
4
Fig. 218
Ensure correct installation position of the angle rings – stepped
contour must always show outwards!!
Preheat bearing inner ring of the pre-assembled planet gear and

line it up, until it is in contact.
Mount planet gear, the large radius/bearing inner ring showing

towards the planet carrier base!
Depending on the version, three or four planet gears are

installed.
The picture shows the version with three planet gears!
Fig. 219
Fix planet gear with snap ring.
Fig. 220
5871 693 012 2/59

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und Achssysteme
2.4.6.2 Version "B"

Planet gear support with angular roller bearing:
2 (Fig.-No. 221 ... No. 223)
1 3
1 = Lower bearing inner ring (with large radius)

2 = Planet gear
3 = Upper bearing ring
4 = Snap ring
Fig. 221
Press in lower bearing inner ring (see Item 1 / Fig.-No. 221),

until it is in contact.
Depending on the version, three or four planet gears are

installed.
The picture shows the version with four planet gears!
Fig. 222
Line up planet gear, fix it with upper bearing inner ring (see Item
3 / Fig.-No. 221) and mount snap ring.
Fig. 223
Oil ring and insert it into the annular groove of the hub (see
arrow).
Fig. 224
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und Achssysteme
Line up pre-assembled planet carrier and fasten it with

cylindrical bolts.
Tightening torque (M 10/8.8) ........... MA = 32 Nm

Tightening torque (M 12/8.8) ........... MA = 55 Nm
Fill the axle with oil as per ZF lubricating- and maintenance

instructions – see Page 0/4 and 0/5!
Fig. 225
2.4.7 Steering angle sensor system:
2.4.7.1 Version "with" angle sensor:

(Sketch-No. 226 ... No. 231)
Legend to Sketch-No. 226:
1 = Angle sensor
2 = Bearing bolt
3 = Lock plate (only for version "with" lock plate
4 = Hexagon bolts
1
1/d 3 Individual parts of the angle sensor (Item 1):
1/a = Sensor housing
1/c 4 1/b = Magnet carrier
1/c = O-ring
1/b 2 1/d = Cover
1/e 1/a 1/e = Pressure spring The compl. foot plate (with O-rings
1/f = Foot plate and connect. cable must be installed
1/g = O-ring prior to mounting the bearing bolt.
1/h = O-ring - see section 2.4.1.1, Page
1/h 1/i = Connect. cable
1/g 1/i/
1/f
Fig. 226
1/a Legend to Sketch-No.227:

3/c 3/b
2/a 1 = Sensor housing (1/a = wide and small
3/d plug fixing)
2 = Magnet carrier (2/a = Item of the adjusting recess/cover)
3 = Cover with pressure spring/snap ring(3/a) and O-ring (3/b)

3/a (3/c = Adjusting lug/magnet carrier, 3/d = adjusting
2 pin/bearing bolt)
3 1
Fig. 227
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Insert sensor housing
Observe plug connection of sensor housing and foot plate - -

overlapping of wide or small plug fixing!
Fig. 228
Insert magnet carrier – the adjusting recess showing upwards

(arrow).
Fig. 229
Insert cover (with pressure spring and O-ring) – with fixing pin
in the fixing bore of the bearing bolt and adjusting lug positioned
in the adjusting recess of the magnet carrier.
Visual check – if bearing bolt and sensor have been correctly

mounted, the arrow on the cover must show towards the axle
centre!
Fig. 230
Place retaining plate (only for version "with" retaining plate).
Fasten cover.
The picture shows the version "with" retaining plate!
Tightening torque M6/8.8) ............. MA = 10 Nm
Functional check of the steering angle sensor system as

Fig. 231 directed by the vehicle manufacturer!
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und Achssysteme
Only for version "with" discs.
Mount discs.
Tightening torque(M16/8.8) ............. MA = 195 Nm
Fig. 232
2.4.7.2 Version "with" dual sensors:

(Sketch-No. 233 ... No. 247)
4
2 1 Legend to Sketch-No. 233:
1 = Position – sensor(inductive transmitter) No. 1

2 = Position – sensor (inductive transmitter) No. 2
3 = Cable harness with sensor designation No. 1 or No. 2
4 = Compl. plugs
2 1 3
Fig. 233
2 Legend to Sketch-No.. 234:
1 = Sensor (inductive transmitter)

1 2 = Bearing bolt
3 = Fork head (axle casing)
7 5 = Locking disc
6 = Indented rings (2 units)
7 = Cover
3 X = Set adjusting measure (air gap) 0.3 ... 0.4 mm
X 4 5 6 for wheel head position 0° ± 5°
Fig. 234
Bring output into position O° ± 5° .
Determine measure "A" from plane face/recess of the axle casing

to contact face/bearing bolt using a plug gage.
- to that end, suitably position measuring ring prior to
determining the distance.
(S) Plug gage 5870 200 071
Fig. 235
5871 693 012 2/63

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Determine measure"A" from front face/plug gage to measuring

ring.
Measure "A" e.g. ............................. 24.65 mm
(S) Digital depth gage 200 mm 5870 200 072
Fig. 236
Determine measure "B" from front face/inductive transmitter to

adjusting shim.
Measure "B" e.g. ............................ 25.50 mm
(S) Digital depth gage 200 mm 5870 200 072
Measure "B" e.g.................................. 25.50 mm

Measure"A" e.g. ................................ .. - 24.65 mm
Difference ......................................... 0.85 mm
Fig. 237 Adjust. measure (0.3 ... 0.4 mm gap) e.g. + 0.35 mm
Result: adjust. shim thickness "S" = 1.20 mm
Pre-assemble inductive transmitter – line up indented rings,

insert locking disc and line up determined adjusting spacer
(also see Sketch-No. 234).
Legend to picture:
1 = Inductive transmitter
3 = Locking disc
4 = Indented rings

Fig. 238 Ensure correct installation position of the indented rings –
indentation showing towards the cable (see arrow)!
Introduce pre-assembled inductive transmitter and fix it without

gap using indented rings.

Ensure correct installation position of the two inductive
transmitters No. 1 and No. 2 – see Sketch-No. 233!
Fig. 239
5871 693 012 2/64

Geschäftsbereich
und Achssysteme
Analogously mount second inductive transmitter.
In case of missing plug designation – mark plugs of both

inductive transmitters - No. 1 or No. 2
(Assembly aid – also see Sketch-No. 233)!
Fig. 240
Introduce cables of the inductive transmitters through the duct of

the axle casing..
Fig. 241
Mount cable harness
Observe installation position or plug connection!

Connect plug with the respective designation 1 or 2 at the cable
harness to the respective inductive transmitter 1 or 2, see Sketch-
No. 233 and assembly instructions Fig.-No. 240!
Fig. 242 2.4.7.2.1 Check ON/OFF – switching function of the

inductive transmitters
Apply supply voltage (5 - 30 V), depending on the vehicle

equipment (specification/vehicle manufacturer)
Wheel head/steering angle 0°

- both sensors in switching position "ON"
Turn wheel head up to disconnection.
ON/OFF switch point of the sensors to be taken from the

information of the vehicle manufacturer.
(S) Indicator device 5870 221 152

Fig. 243 (S) Adapter cable 5870 221 144
5871 693 012 2/65

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Pre-assemble plug – mount seal (2) into plug (1), line up O-ring
(3) and cover (4) (ensure correct installation position) and fix
with retaining ring (5), then line up O-ring (5).
Legend to picture:
1 = Plug
2 = Seal
3 = O-ring
4 = Cover
5 = Retaining ring
6 = O-ring
Fig. 244
Connect pre-assembled plug with the cable harness.
Apply anti-corrosive "Weicon Anti Seize" ZF-ordering-No. 0671

196 001 to contact surface plug cover/axle casing!
Fig. 245
Tighten hexagon bolt.
Tightening torque (M6/8.8) ............. MA = 10 Nm
Fig. 246
Apply sealant (Loctite No. 574) to contact surface cover/axle

casing, place cover and fasten with cylindrical bolts!
Tightening torque (M5/8.8) ................ MA = 5.5 Nm
Fig. 247
5871 693 012 2/66

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2.5 STEERING:
2.5.1 Steering cylinder:
2.5.1.1 Version "A":
(Sketch-No. 248 ... No. 256)
Legend to sketch:
1 = Cylinder ( combined with guide, cannot be disassembled)
2 3 X 2 = Piston rod
1
3 = Guide (can be disassembled)
X = Wrench shoulder
Fig. 248
Legend to sketch:
1 = Cylinder (with guide) 6 = Guide ring

1 2 = Supporting ring 7 = Grooved ring
3 = O-ring 8 = Supporting ring
9 8 7 6 4 = O-ring 9 = Scraper ring
5 = Supporting ring
Mount sealing elements as illustrated into the guide/cylinder.
Sealing lip of the grooved ring must show towards the oil-
5 4
3 2 /pressure compartment!
Fig. 249
Legend to sketch:
1 = Piston rod[ with shrunk piston(1/a) ]

2 = Guide ring
3 = Glyd-ring (with O-ring)
Mount sealing elements into the piston.
1
1/a
2 3 2
Fig. 250
Oil all sealing elements and introduce pre-assembled piston rod

into the cylinder.
Mount piston rod with wrench shoulder (see Item X, Sketch-No.

248) in the direction of the arrow!
Fig. 251
5871 693 012 2/67

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Legend to sketch:
1 = Guide 5 = Grooved ring

2 = O-ring 6 = Supporting ring
4 5 6 7 3 = Supporting ring 7 = Scraper ring
4 = Guide ring 8 = Snap ring(Guide
- see Fig.-No. 254)
Mount sealing elements as illustrated into the guide.
1
2 3 8 The sealing lip of the grooved ring must show towards the oil-
/pressure compartment!
Fig. 252
Oil sealing elements and insert pre-assembled guide.
Introduce guide, until snap ring (guide – also see Fig.-No. 254)
can be mounted into the annular groove of the cylinder.
Fig. 253
Mount snap ring.
Fig. 254
Draw guide into end position using the piston rod..
Fig. 255
5871 693 012 2/68

Geschäftsbereich
und Achssysteme
Fix guide with retaining ring.
Fig. 256
2.5.1.2 Version "B":
(Sketch-No. 257 ... No. 266)
Legend to sketch:
1 = Cylinder (with guide) 4 = Grooved ring

1 2 = Form sealing ring 5 = Guide ring
3 = Form sealing ring 6 = Scraper ring
6 4 5 4
Mount sealing elements as illustrated into the guide/cylinder.
The sealing lip of the grooved ring must show towards the oil-
3

2
Fig. 257
Legend to sketch:
1 = Piston rod[ with shrunk piston(1/a) ]

2 = Guide ring
3 = Form sealing ring (with O-ring)
Mount sealing elements into the piston.

1
1/a
3 2
Fig. 258
Oil all sealing elements and introduce pre-assembled piston rod

into the cylinder.
Mount piston rod with the wrench shoulder (see Item X, Sketch-
No. 248) showing into the direction of the arrow!
Fig. 259
5871 693 012 2/69

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und Achssysteme
Legend to sketch:
1 = Guide
2 = Form sealing ring
3 4 3 5 3 = Guide ring
4 = Grooved ring
5 = Scraper ring
Mount sealing elements as illustrated into the guide.
2
1 The sealing lip of the grooved ring must show towards the oil-
Fig. 260
Oil sealing elements and insert pre-assembled guide.
Introduce guide, until snap ring (guide – also see Fig. 262) can
be mounted into the annular groove of the cylinder.
Fig. 261
Mount snap ring ( also see Sketch-No. 265 - Item. 4).
Fig. 262
Draw guide into end position using the piston rod. .
Fig. 263
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Insert O-ring (see Sketch-No. 265 - Item 5)
Fig. 264
Legend to sketch:
1 = Cylinder
2 = Piston rod
3 = Guide
4 = Snap ring (guide)
5 = O-ring
6 = Retaining ring (guide fixing)
1 2 3 4 5 6
Fig. 265
Fix guide with retaining ring (also see Sketch-No. 265 – Item 6)
.
(S) External plies set 5870 900 015
Fig. 266
Apply sealing compound (Loctite No. 574) in area X – about 50

... 55 mm from centre of the connection bore (also see Fig.-No.
268).
X
Fig. 267
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Insert complete steering cylinder.
Ensure radial installation position of the steering cylinder – the

connection bores of steering cylinder and axle casing must
correspond!
Fig. 268
Fasten steering cylinder with "new" grooved nut (self-securing –

permitted to be used only once).
Tightening torque (M 65x2) ............. MA = 1000 Nm
(S) Grooved nut wrench (M 65x2) 5870 401 128
Fig. 269 Tightening torque for axial joint/track rod fixing:
Counter nut:
M24x1.5 ................................ MA = 290 Nm
M28x1.5 ................................ MA = 390 Nm
Clip:
M10x1 ................................... MA = 50 Nm
Legend to sketch:
1 = Track rod
2 = Hexagon nut or clip (depending on the version)
3 = Axial joint
The track must be set as directed by the vehicle manufacturer!

Fig. 270
For offset track rods – ensure correct installation position/offset

– see disassembly instruction Page 1/2 , Fig.-No. 6 or
perspective representation in the respective spare parts list!
Mount both track rods into the piston rod.
Secure connection piston rod/axial joint with Loctite No. 243) –

over about 3 threads!
Tightening torque (M22x1.5 .................. MA = 300 Nm

Fig. 271
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Suspend track rod in joint housing and fix with "new" hexagon
nut (self-securing – use permitted only once).

Fig. 272
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2.5.2 Set and check STEERING:
A2
5 2 X 5
Y
4 4
52° -2°
3
1 A1 1
Fig. 273
2.5.2.1 Basic setting of the track:

Position piston rod in the centre position = Measure "X"
Determine measure = X (measured from front face/guide to front face/axial joint).
Piston (rod) stop/right in cylinder Measure I e.g. .............................. 254 mm

Piston (rod) stop/right in cylinder Measure II e.g. .............................. - 2 mm
Result ................................................................................................... = 252 mm
: 2
Measure "X" e.g. ................................................................................. = 126 mm
During track setting, the axial position (centre position of the piston rod must no more be changed!
Mount measuring ledges (1) centrally to the axle and horizontally.

Fasten measuring device (3) to the input flange.
Unfix hexagon nuts or clip (2) and set length of the track rod (axial joint), until 0° can be read
at the measuring device (3) (corresponds to a track setting of "zero" mm).
Make setting on either side!
(S) Measuring device 5870 200 033

(S) Measuring ledges 5870 200 029
Check track setting:
Determine measure A1.

Turn both outputs by 180° - Measure A2 must be identical to Measure A1.
Measure "Y" = distance wheel centre to rim horn.
If a preliminary or secondary track setting should be necessary, observe the instructions of the vehicle manufacturer.
Then, fix again both track rods/axial joint with hexagon nut (counter nut) or clip.
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2.5.2.2 Setting the steering angle:

If the track must be set, this must be done "prior to" setting the steering angle!
Set steering angle on either output side !
Make setting always on the curve-internal output side (see Sketch-No. 274) !
4
2
3
1
Fig. 274 Legend to sketch:
1 = Measuring ledge 5870 200 029
2 = Flange holder 5870 510 035
Required only for flange version with hub spline
3 = Measuring device 5870 200 033

4 = Stop screw (curve-internal stop)
5 = Stop screw (curve external stop)
Mount measuring ledge (1) central to the axle and horizontally.

Fasten measuring device (3) to the input flange (2) or flange holder.
Turn output, until the steering angle to be set (e.g. 52°- 2°) can be read from the measuring device.
Then, place stop screw (4) and – only for version "with" double stop – at the opposite output, stop screw (5) and counter with
hexagon nut.
Tightening torque (M18x1.5) ................................ MA = 150 Nm
The value of the steering angle to be set can be taken from the instructions of the vehicle manufacturer!
2 5.2.3 Check tightness of the steering:

Check steering (sealing elements) in both steering directions for tightness using a HP-pump.
Connect HP-pump and build up a test pressure of p = 200 bar (breathing the pressure compartment).
Close shut-off valve (connection/HP-pump).
During a test time of 20 sec., a pressure drop of max. 5 bar is admissible!

An outer leakage is not permitted to occur!
Test medium: Engine oil SAE 10 W

MIL-L 2104 C / MIL-L 46152
(S) HP-pump 5870 287 007
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2 2.6 SELF-ALIGNING BEARING:

1 1
2.6.1 Version "A":
(Sketch-No. 275)
3
Legend to sketch:
1 = Bush
2 = Lubricating nipple
3 = Axle casing
Mount both bushes (1) in a flush manner.

Fig. 275 Mount lubricating nipple (2).
2.6.2 Version "B":
Insert both bushes in a flush manner with jointing compound

(Loctite No. 649).
Ensure correct installation position - lubricating bore(bush (see

arrow) must correspond with lubricating nipple position!
Position of the lubricating nipples – depending o the axle

version!
Fig. 276
2.6.3 Version "C":

4 3 5 6 2 1 2 6 5 3 4
Legend to Sketch-No. 277 ... No. 280:
1 = Axle casing
7 2 = Buffer disc
3 = Bush
4 = Bearing support
5 = Bush
6 = V-ring
7 = O-ring
Fig. 277
Bring both buffer discs (2) and both heated up bushes (3) into
contact – press, if necessary.
2 2
3 3
Heat up bushes to max. 100° !
Fig. 278
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Pre-assemble bearing support.

Grease bush (5) and insert it into the bearing support,
line up V-ring (6) and insert O-ring (7 – only at the rear bearing
support) .
Insert both centering sleeves (arrows) .
Fig. 279
Line up both pre-assembled bearing supports.
Fig. 280
Only for securing during transport:
Turn bearing supports, line up hexagon bolts (with shims) and

fix bearing supports with strap.
Fig. 281
4 2.6.4 Version "D":

1
2 3
Legend to Sketch-No. 282 ... No. 284:
1 = Bush
2 = Bush
3 = Protection sleeve
4 = Axle casing
Fig. 282
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Mount bushes (1) and (2), ensuring the correct installation

1 position and the maximally admissible heating up temperature.
2
Heating up temperature of the bushes = max. 100° C.
Ensure correct installation position of the bush (1) - large

chamfer (arrow) showing towards the radius!
Installation measure "X" = 8 + 0.5 mm
Installation position of the bush (2) = flush!

"X"
Fig. 283
Line up protection sleeve and fasten with hexagon bolt
Tightening torque (M10/10.9) ............. MA = 68 Nm
Fig. 284
2.7 BREATHER:
Detail "X"
2.7.1 Version "A" (plug-type version):
Insert breather – see detail "X".
The use of the specified support ensures an exact assembly and

proper functioning (risk of damaging) of the breather !
(S) Support 5870 048 250

Fig. 285
2.7.2 Version "B" (screw-type version):

Detail "X"
Mount breather (detail "X") with sealant "Spezialtyp 1108" ZF-
ordering-No. 0666 790 047.
Arrow position of the breather – depending on the axle version,
see representation in the respective spare parts list.
Fig. 286
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Screw in all oil draining- and filling screws at axle casing and
planet carrier using "new" O-rings.
Tightening torque (M36x1.5) ..................... MA = 150 Nm
Fig. 287
Prior to starting the operation of the axles, the ZF

instructions for lubrication and maintenance – see Page 0/4
and 0/5 – as well as the instructions and information given by
the vehicle manufacturer must be observed!
5871 693 012 2/79

Gearbox ZF (5871 693 012 AS-2025-2075)

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Ordering-No.

: 5871 693 012

INFORMATION TO THE REPAIR INSTRUCTIONS

Abt.: ASTDM / Section : ASTDM

1. Continuously trained staff

2. Prescribed facilities, e.g. special tools

3. Genuine ZF-spare parts meeting the latest state of development

5871 693 012 0/1

5871 693 012 0/2

Structure of the Service Manual

Important information concerning the work safety

This symbol indicates situations where lacking care can entail

5871 693 012 0/3

LUBRICATION- AND MAINTENANCE INSTRUCTIONS

2.1 Oil drain hole - output

To avoid injuries due to a possible pressure build-up

2.2 Oil filling - output

Place new O-ring onto screw plug (1) and.

5871 693 012 0/4

2.3 Oil drain hole – axle casing

Unfix drain plug (2) and drain oil.

Provide drain plug (2)with new O-ring and mount it.

3. Oil changing interval:

3.1 Grease lubrication points:

5. Oil level check:

6. Oil (brake medium) for multi-disc brake (driven end):

As specified and directed by the vehicle manufacturer.

TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG

Ideales Tragbild d.h. die Ritzeldistanz stimmt

Ideal tooth-contact pattern i.e. pinion distance is correct

L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte

Bild / Figure 1/3/5 Bild / Figure 1

Coast side (concave)

Côté poussé (concave)

Bild / Figure 2/4/6 Bild / Figure 2

Drive side (convex)

Côté entraîné (convexe)

5871 693 012 0/6

Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden

Pinion distance must be increased Pinion distance must be decreased

Bild / Figure 3 Bild / Figure 5

Bild / Figure 4 Bild / Figure 6

5871 693 012 0/7

LETTERING OF THE TYPE PLATE

INFORMATION TO ITEM 6: See ZF list of lubricants for ZF-axles TE - ML 05 !

INFORMATION FOR SPARE PARTS ORDERING

REFERENCE: Items 1, 2 and 3 may be taken from the type plate.

5871 693 012 0/8

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)

1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5.560 lb / in ( pound per inch )

5871 693 012 0/9

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Density lineaire en kg/m; Density superficielle en t/m2

Begriff Formelzeichen neu alt Umrechnung Bemerkungen

5871 693 012 0/10

TORQUE LIMITS FOR SCREWS (IN Nm) AS PER ZF-STANDARD 148

Metric ISO-standard thread DIN 13, sheet 13

Size 8.8 10.9 12.9

5871 693 012 0/11