Front leading and trailing axles

2002 1 2 3 4 5 6 7 9 10 11 12

Repair manual
81.99598-5442 2nd Edition H8
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung H 8 (2. Ausgabe)
Dachauer Str. 667 oder Postfach 50 06 20 Nicht angetriebene,
80995 MÜNCHEN 80995 MÜNCHEN Vorder-Vorlauf und Nachlaufachsen
VO.., VOK.., LO.., LOL.., NOL.., NO
- englisch -
Printed in Germany
Repair manual H 8
2nd Edition

Non-driven,
front leading and trailing axles

VO.., VOK.., LO.., LOL.., NOL.., NO..

81.99598-5442
PREFACE / PRINTER’S IMPRINT

The purpose of these instructions is to enable repairs to vehicles and components to be correctly performed.

The necessary technical knowledge for dealing with vehicles and components was assumed in the production
of this document.

The illustrations and associated descriptions refer to typical photographs taken at the time and do not
correspond to the component in question, but are nevertheless not incorrect. Repairs are to be appropriately
planned and performed In such cases.

Repairs to complex add-on components are to be left to our Customer Service or the customer service of the
manufacturer. These components are referred to separately in the text.

Important instructions that affect technical safety and the safety of personnel are highlighted as follows.

WARNING
Refers to work and operating procedures that must be maintained to avoid injury to personnel.

CAUTION
Refers to work and operating procedures that must be maintained to avoid damage or destruction
of equipment.

Note
Explanatory description useful for an understanding of the work or procedure to be performed.

The general safety precautions are to be observed for all repair work.

With best wishes

MAN Nutzfahrzeuge Aktiengesellschaft
Werk München

© 2002 MAN Nutzfahrzeuge Aktiengesellschaft

The right to make technical changes in line with developments is reserved.

Reprinting, reproduction or translation, including in part, is not permitted without the written permission of
MAN. All rights under copyright law remain the express property of MAN.

VSWD 1 /grü 03.2002 Satz: emes GmbH Druck: MAN-Werksdruckerei

Friedrichshafen

II
 TABLE OF CONTENTS

Contents Section/Page

Introduction
Safety precautions .................................................................................................................................. 1 – 1
Presentation of components ................................................................................................................... 1 – 5

Axle alignment
Checking and setting values for axle alignment ............................................................................... 2 – 25

Front axle
Removing and refitting front axle ..................................................................................................... 3 – 31

Wheel hub assembly

Removing and refitting brake disk .................................................................................................... 4 – 39
Checking hub unit bearing for wear ................................................................................................. 4 – 45
Removing and refitting hub unit bearing .......................................................................................... 4 – 47
Remove the hub unit bearing using hydraulic force ......................................................................... 4 – 53

Stub axle
Checking end float of stub axle ........................................................................................................ 5 – 59
Removing and refitting axle knuckle ................................................................................................ 5 – 61
Removing and refitting stub axle bearing ......................................................................................... 5 – 67
Removing and refitting axle end (LO, NO) ...................................................................................... 5 – 71

Steering / track-rod arms and track-rods

Check steering track-rod arms and track-rods ................................................................................. 6 – 75
Removing and refitting track-rod joint .............................................................................................. 6 – 79
Removing and refitting steering and track rod arms ........................................................................ 6 – 83

III
 INDEX

Index Page

A
ABS speed sensor ....................................................................................................................................... 44
Axle alignment ............................................................................................................................................. 23
Axle end ....................................................................................................................................................... 71
Axle illustrations ........................................................................................................................................... 14
Axle type, description ..................................................................................................................................... 9

B
Brake disk .................................................................................................................................................... 39

C
Camber, description ..................................................................................................................................... 12
Castor, description ....................................................................................................................................... 12
Characteristic data ......................................................................................................................................... 8
Checking and setting values for axle alignment ........................................................................................... 25

H
Hub unit bearing ........................................................................................................................................... 47
Hub unit bearing, measurement of end float ................................................................................................ 46

I
Identification plate/type marking .................................................................................................................... 6

K
Kingpin inclination, description ..................................................................................................................... 12

L
Leakage, hub unit bearing ........................................................................................................................... 46

N
Needle bushing, stub axle bottom bearing ................................................................................................... 69
Needle bushing, stub axle top bearing ......................................................................................................... 69
Noise check, hub unit bearing ...................................................................................................................... 46

O
Overview of variants ...................................................................................................................................... 5

P
Presentation of components .......................................................................................................................... 5

R
Remove brake disk using extractor bolts ..................................................................................................... 42
Remove brake disk using hydraulic force .................................................................................................... 43
Remove wheel flange .................................................................................................................................. 42
Removing and refitting front axle ................................................................................................................. 31
Removing and refitting track rod joint .......................................................................................................... 79
Removing the hub unit bearing using hydraulic force .................................................................................. 53

S
Safety precautions ......................................................................................................................................... 1
Slotted nut .................................................................................................................................................... 50
Steering geometry, description .................................................................................................................... 11

V
INDEX

Index Page

Steering rods and track rods ....................................................................................................................... 83

Stub axle ...................................................................................................................................................... 61
Stub axle bearing ......................................................................................................................................... 67
Stub axle end float, check ........................................................................................................................... 59
Stub axle, end float settings ........................................................................................................................ 65

T
Toe-difference angle, description ................................................................................................................ 13
Toe-in, description ....................................................................................................................................... 11
Track rod and steering arm ......................................................................................................................... 83
Track rod end, remove using hydraulic force .............................................................................................. 34
Track rod end, remove using mechanical force ........................................................................................... 34
Track rod joint, fit ......................................................................................................................................... 82
Track rod joint, remove using hydraulic force .............................................................................................. 81
Track rod joint, remove using mechanical force .......................................................................................... 81
Track rod with fine setting ............................................................................................................................ 77
Track rod, check for wear ............................................................................................................................ 76
Track rod, check of end float ....................................................................................................................... 77
Track rod/track rod joint, check ............................................................................................................. 75, 76

W
Wear check, hub unit bearing ...................................................................................................................... 45
Wheel flange ................................................................................................................................................ 42

VI
 SAFETY PRECAUTIONS

INTRODUCTION 1

SAFETY PRECAUTIONS 1

General
Dealing with trucks and buses and the associated operating equipment presents no problems provided the
personnel involved in operating, maintenance and repair are suitably trained and aware.

Important instructions necessary for the avoidance of accidents involving personnel, equipment and the
environment are summarized in the following and arranged according to important points. These are only a
short extract from the various accident regulations and do not replace same. Needless to say all other
safety regulations observed and appropriate measures taken.
Additional direct information on dangers is provided by means of instructions at possible danger points.

Important:
Should an accident occur despite all precautionary measures, particularly due to contact with caustic acids,
the penetration of fuel into the skin, scalding with hot oil, anti-freeze liquid in the eyes etc., call a doctor
immediately.

1. Rules for the prevention of accidents involving injury to persons!

• Secure assemblies when they are to be removed.
• Support the chassis when working on the air suspension or suspension system.
• Keep components, ladders, steps, platforms and their environment free of oil and
grease. Accidents due to slipping can have serious consequences.

Only authorized, skilled personnel may carry out testing, adjustments and repairs

When working on the brake system

• Depending on the type of work on the brake system, carry out a visual examination,
functional test and efficiency test within the meaning of the Safety Testing
Guideline (SP).
• Do a functional test of ABS/ASR systems using a suitable test system
(e.g. MAN-cats).
• Collect leaking hydraulic oil and brake fluid.
• Hydraulic oil/brake fluid is toxic!
Do not allow it to come into contact with food or open wounds.
• Hydraulic oil/brake fluid is special waste!
Observe safety rules for prevention of environmental pollution.

When running the engine

• Only authorized personnel may start and operate the engine.
• When an engine is running do not get too close to rotating parts. Wear closely-fitting
work clothing. Ensure adequate ventilation in enclosed rooms.
• Do not touch components which have run hot with bare hands. There is a danger of
burning! Do not work with bare hands particularly when changing oil (components at
operating temperature).
• Only open the coolant circuit when the engine has cooled down.

Suspended loads
• Nobody may stand under components suspended from the hook of a crane. Keep
lifting gear in good condition.

High-pressure pipes
• Do not attempt to tighten or undo pipes and hoses (lubricating oil circuits, cooling
circuits and hydraulic oil circuits) under pressure. There is a risk of injury from
escaping fluids!
• When checking the injectors, do not position the hands in the way of the stream of
fuel. Do not inhale fuel vapours.

1–1
SAFETY PRECAUTIONS

When working on the vehicle electrical system

• The battery must always be disconnected when working on the electrical system of
the vehicle. The earth cable is to be disconnected first and reconnected last.

WARNING! Battery gases are explosive!

There can be a build-up of explosive gases in closed battery boxes. Increased caution is
necessary after extended running and after battery charging using a charger. When
disconnecting a battery, any continuous consumers, tachographs etc. that cannot be
switched off can cause sparks which will ignite the gas. Blow out the battery box with
compressed air before disconnecting the battery!

• Tow vehicles only with the batteries connected (minimum charge 40%)! Do not use
quick chargers for starting! Batteries should only be rapidly charged with the positive
and negative leads disconnected!
• Avoid short-circuits due to incorrect polarity or metal objects (spanners, pliers etc.)
being placed on the battery terminals.
• Disconnect the batteries on parked vehicles or charge every 4 weeks.

WARNING! Battery acid is toxic and caustic!

Wear suitable protective clothing (gloves) when handling batteries. Do not tilt batteries
as this may cause acid to leak.

• Measure voltages using only appropriate equipment! The impedance of the

measuring device should be at least 10 MW.
• You must remove or connect wiring harness plugs of electronic control units only
when the ignition is off!

Electric welding
• Connect the "ANTIZAP-SERVICE-WÄCHTER" protective device (MAN part number
80.78010.0002) according to the instructions supplied with the device.
• If this device is not available, disconnect the batteries at the terminals and make an
electrically conductive connection between the negative and positive leads.
• In all cases, earth the welder as close as possible to the weld point. Do not route
welder cables parallel to vehicle electrical cables.
• The chassis is not designed as an earth return! When add-ons are retrofitted, e.g.
wheelchair lifts, extra earth leads of adequate diameter should be incorporated
because the earth connection will otherwise go via winch cables, wire harnesses,
gear lever, gearwheels, etc. This will cause serious damage.

CAUTION! Polyamide pipes - Risk of fire and damage!

• The adjacent warning notice is to be found on the tank filling flaps for the diesel fuel
or heating oil. It warns against welding or drilling in the vicinity of plastic tubing.

Painting
• When painting, electronic components must be exposed to high temperatures only for
a short time (max. 95 °C); up to about two hours is permissible at a maximum of
85 °C. Disconnect batteries.

With cab tilted

• Keep the tilt area in front of the cab clear.
• When tilting keep clear of the area between the cab and chassis, danger area!
• Always tilt the cab past the tilt point to the end position.

Air-conditioning system
• Refrigerant and vapours are injurious to health. Avoid contact and protect eyes and
hands.
• Do not release gaseous refrigerant in enclosed rooms.
• Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.

1–2
 SAFETY PRECAUTIONS

2. Notes on the avoidance of damage and premature wear to components

• Do not load components beyond the load for which they are designed in normal use. Do not overload.
• If running faults occur, determine the cause immediately and rectify, so that no further damage arises.
• Clean components thoroughly before repair. Make sure that no dirt, sand or foreign bodies enter
components during repair.
• Use only original spare parts. The use of "just as good parts" of third-party origin can cause serious
damage under certain circumstances, for which the workshop carrying out the work is responsible. Note
the provisions of the "Limitation of liability for parts and accessories" chapter.
• Do not allow components to dry out, i.e. do not run without adequate lubrication.
• Do not run engines without adequate coolant.
• Components that are not ready for operation are to be provided with a suitable warning notice.
• Use only operation media (engine and gear oil, antifreeze and corrosion protective agents) approved by
MAN. Ensure cleanliness at all times.
• Adhere to the specified maintenance intervals.
• Do fill engine/gear oil above the maximum mark. Do not exceed the maximum permissible operating
inclination.
• Failure to comply can cause serious damage to the component.

3. Limitation of liability for parts and accessories

It is in your own interest that we recommend only using accessories specifically approved by MAN and
original MAN parts on your MAN vehicle. The reliability, safety and suitability of these accessories and parts
has been determined specifically for MAN vehicles. In the case of other products – even if they have TÜV
approval or are licensed by an official authority - we cannot assess them or vouch for them despite continuous
scrutiny of the market.

Bodywork
In the case of standard or customized bodywork, the safety rules of the particular manufacturer must be
observed without fail.

Laying up or storage
When laying up or storing buses or trucks for periods of longer than three months, particular measures are
required in compliance with the factory standard MAN-M 3069 Part 3.

4. Handling brake pads/linings and similar parts

• The mechanical machining of brake pads/linings, particularly turning and grinding, and also blowing out
wheel brakes can cause dust that is injurious to health to be released.
• To avoid any possible injury to health, take suitable safety measures and note the following safety advice:
• If possible work outdoors or in well ventilated rooms!
• If possible use hand operated or slowly-rotating equipment, if necessary equipped with a dust collecting
device!
• If fast-rotating equipment is used, this equipment should always be provided with such devices.
• Moisten parts to be machined before cutting or drilling!
• Dispose of brake linings/pads harmlessly as special waste!

1–3
SAFETY PRECAUTIONS

5. Precautions for the avoidance of damage to health and the environment

For cooling fluid

Treat undiluted antifreeze agent as special waste. Observe the regulations of the appropriate local authority
when disposing of used coolant fluid (antifreeze agent mixed with water).

Cleaning coolant circuit

Cleaning fluid and flushing water may be disposed of in drains only if this is not forbidden by particular local
regulations. A condition in any case is that the cleaning fluid and flushing water must be passed through an
oil separator with a sludge trap.

Cleaning filter elements

When blowing out the filter element make sure that the filter dust is drawn off by means of a vacuum system
or collected in a dust collecting bag. Otherwise wear respiratory protection. When washing the element,
protect hands by wearing rubber gloves or using hand protection cream, because the cleaning agent is a
powerful degreaser.

Engine/gear oil, filter cartridges, boxes and inserts, desiccant inserts

Dispose of old oil only by old oil recycling. Make absolutely certain that oil does not reach drains or penetrate
the ground as this can cause infectious contamination of drinking water. Filter inserts, boxes and cartridges
(oil and fuel filters, desiccant inserts of air driers) are special waste and must be disposed of correctly. The
regulations of the responsible local authority must be adhered to.

Used engine oil/gear oil

Prolonged or repeated skin contact with any kind of engine/gear oil causes degreasing of the skin. This can
lead to drying out, irritation or skin inflammation.
Used engine oil is also a dangerous substance that has been shown in tests on animals to be carcinogenic.

Precautionary measures for protection of your health

• Avoid prolonged, excessive or repeated skin contact with used oils.
• Protect your skin by using a suitable skin protective agent or by wearing protective gloves.
• Clean skin contaminated by engine oil.
• Wash thoroughly with soap and water.
• A nailbrush is an effective aid.
• Special hand cleaning agents make the cleaning of dirty hands easier.
• Do not use gasoline, diesel fuel, gas oil or thinners or solvents.
• After cleaning your hands protect them by using a skin cream containing grease.
• Change oil-soaked clothing and shoes.
• Do not put oily rags in the pockets of your clothing.

Make sure that used engine oil/gear oil is correctly disposed of.
- Oils are substances hazardous to water -

Therefore do not pour old oil on the ground, into waterways, into sewers or drains. Violations are punishable.
Carefully collect and dispose of used oil. Information on collection points is available from the vendor, supplier
or local authority.

Extract from "Information Notice on Handling Used Engine Oil"

MINERALÖLWIRTSCHAFTSVERBAND E.V.
Steindamm 71, D-20099 Hamburg

1–4
 OVERVIEW OF VARIANTS

PRESENTATION OF COMPONENTS 1

Overview of variants

The following variants are covered by these instructions.

Basic designation + variant Suspension Brakes

TG-A

VOK-08-01/02 Air Disk brakes

VOK-08-03/04 Spring suspension Disk brakes

VOK 08-15/16 Air Disk brakes

VOK-09-01/02/05/06/07/08 Spring suspension Disk brakes

VO-09-01/0213/14 Spring suspension Disk brakes

LO-08-02 Air Disk brakes

LOL-08-02 Air Disk brakes

NOL-08-02/03/04/05/06 Air Disk brakes

NO-08-04 Air Disk brakes

Bus

VOK-06-B-01 Air Disk brakes

VOK-07-B-01/02/03 Air Disk brakes

VOK-07-F-01 Air Disk brakes

NOL-06-B-01 Air Disk brakes

1–5
IDENTIFICATION PLATE / TYPE MARKING

Identification plate/type marking

Identification plate

(1) Manufacturer
(2) Serial number
(3) Axle type
(4) Part number
(5) Dia. of brake cylinder

The serial number (FZ) is a serial numbering of the

complete axle production. This enables modifications
to the unit to be precisely is dealt with

The brake cylinder diameter on hydraulic cylinders is

given in mm and given in inches on diaphragm
cylinders.

On axles with disk brakes, the last four digits of the part number are given under items (4) and (5).

The identification plate for non-driven steered axles is attached to the axle body, on left when viewed in
direction travel.

1–6
 IDENTIFICATION PLATE / TYPE MARKING

Type of marking
Example V O K 08 -- -- 02
Classification figure 1 2 3 4 5 6 7

The example shows a steerable front axle, non-driven, dropped, with 8t axle load and ident. number 02.

Classification figure
1 Installation
2 Drive
3 Attribute
4 Technically permissible maximum axle load in t
5 Technically permissible combined load in t
6 Application-related allowance
7 Ident. number for different axle variants

Meaning of classification figures

1 Installation:
V= Front axle
H= Rear axle
L= Front axle (leading axle)
N= Trailing axle

2 Drive:
O= Without drive
Y= Hypoid transmission
P= Planetary gearing
H= Hydrostatic drive
U= Portal drive

3 Attribute:
D= Drive through
G= VP-09 cast axle bracket
K= Dropped axle (straight axles [drop equal to/less than 35 mm] are regarded as standard and
are not given)
L= Steered (steered is standard for front axles and is not given)
R= Tubular axle
S= Swinging-arm axle (independent wheel suspension)

4 Technically permissible maximum axle load in t (Shown to two places)

5 Technically permissible combined load in t: (only applies to rear axles)

6 Application-related allowance:
B= Bus
E= Single tyred
G= Off-road
F= Third party (development and production for outside companies)

7 Ident. number for different axle variants:

1–7
CHARACTERISTIC DATA

Characteristic data

VOK-08-01/02
Axle weight without wheels approx. 455 kg

VOK-08-03/04
Axle weight without wheels approx. 440 kg

VOK-08-15/16
Axle weight without wheels approx. 455 kg

VOK-09-01/02/05/06/07/08
Axle weight without wheels approx. 444 kg

VO-09-01/02/13/14
Axle weight without wheels approx. 440 kg

LOL-08-01/02/03
Axle weight without wheels approx. 440 kg

NOL-08-01/02/03/04/05/06
Axle weight without wheels approx. 440 kg

Note
Axle weights not given here were not available the time of going to press.

1–8
 DESCRIPTION

Description

Axle type

(1) Forged axle body

(2) Axle tube

There are two types of rigid axle bodies:

• Forged axle body (straight or dropped)
• Axle tube (straight trailing axle)

The front axles are basically steered, the leading axles are hydraulically steered as standard.
Trailing axles can be either non-steered or hydraulically steered.

1–9
DESCRIPTION

Disk brakes, wheel suspension and steering stub (VOK-08)

A maintenance-free hub unit (1) is built in on the "LUCAS D-ELSA" disk brakes. The hub unit is lubricated for
life and enclosed. There is now no specified annual grease change. The hub unit stays on the stub axle as a
complete assembly during a brake disk (2) change.

The stub axle bolts (4) are triple-stepped bolts and are inserted from above with the axle installed. The axial
bearing (thrust bearing) and the bottom needle bearing form one unit. The stub axle with the needle bearing
bush and the stepped stub axle bolts are maintenance-free.

The grease nipples (3) and (6) are required for initial assembly lubrication and are protected by sealing caps.

The shims (5) are located between the axial bearing and axle knuckle. Disk brakes, wheel suspension and
stub axle are identical for front leading and trailing axles.

1 – 10
 DESCRIPTION

Description of steering geometry

Toe-in

Toe-in is the alignment of the front wheels in the driving direction. If the wheels are further apart at the back
than at the front, measured at wheel centre height, i.e. they run together in the driving direction, this is known
as toe-in.
B-A= positive value or A less than B.

If there is "negative toe-in" (toe-out), the wheels are further apart at the front than at the back. This is
measured in mm or angular minutes, depending on the measuring equipment.
Toe-out
B-A= negative value or A is greater than B.

1 – 11
DESCRIPTION

Wheel camber

Wheel camber is the deviation of the wheel plane from the vertical. With positive camber (A) the wheel plane
is inclined outwards at the top and with negative camber (B) it is inclined inwards at the top. Camber
adjustment is not possible on rigid axles.

Kingpin inclination

The kingpin inclination is the inwards inclination of the kingpin axis at the top relative to the vertical. No
adjustment is possible. The wheel camber and kingpin inclination determine the kingpin offset R.

Castor

The castor is the inclination of the kingpin axis at the top viewed in the direction of travel. This is normally
rearward (positive camber), but rarely forwards (negative camber). Because the kingpin axis at point A meets
the roadway before the vertical through the wheel (point B), the wheel is "pulled" and its running is more
stable. The greater the castor the better the directional stability, but also the greater the aligning force of the
steering.

1 – 12
 DESCRIPTION

Toe-difference angle

The toe-difference angle is the difference between the steer angle of the wheel on the inside of the curve and
the steer angle of the wheel on the outside of the curve. A comparison of the toe-difference angle for right
and left steer angles provides information on the steering trapeze and enables faults in steering components
(track-rod arm, track rod) to be detected.

1 – 13
ILLUSTRATIONS COMPONENTS

Axle illustrations

VOK-08 longitudinal section

(1) Flange
(2) Hub-unit bearing
(3) Brake disk
(4) Brake cylinder
(5) Stub axle pins

1 – 14
 ILLUSTRATIONS COMPONENTS

VOK-08 cross section, left wheel part

(1) Brake calliper

(2) Drop arm
(3) Track-rod arm
(4) Track rod

1 – 15
ILLUSTRATIONS COMPONENTS

NOL-08 longitudinal section

(1) Flange
(2) Hub-unit bearing
(3) Brake disk
(4) Brake cylinder
(5) Stub axle pin

1 – 16
 ILLUSTRATIONS COMPONENTS

NOL-08 cross section, left wheel part

(1) Brake calliper

(2) Track-rod arm
(3) Track rod
(4) Drop arm

1 – 17
ILLUSTRATIONS COMPONENTS

NO-08 longitudinal section

(1) Flange
(2) Hub-unit bearing
(3) Brake disk
(4) Brake cylinder

1 – 18
 ILLUSTRATIONS COMPONENTS

NO-08 cross section, left wheel part

(1) Brake calliper

(2) Axle end

1 – 19
ILLUSTRATIONS COMPONENTS

VO-09 longitudinal section, drum brakes

(1) Brake drum

(2) Brake camshaft
(3) Stub axle pins
(4) Brake shoe bolts
(5) Hub-unit bearing

1 – 20
 ILLUSTRATIONS COMPONENTS

VO-09 cross section, drum brakes, left wheel part

(1) Diaphragm cylinder

(2) Linkage actuator
(3) Drop arm
(4) Track-rod arm
(5) Track rod

1 – 21
 AXLE ALIGNMENT

AXLE ALIGNMENT 2

(1) Gauge rod, front

(2) Laser projector
(3) Gauge, rear

2 – 23
AXLE ALIGNMENT

Space for changes / new features / notices

2 – 24
 AXLE ALIGNMENT

CHECKING AND SETTING VALUES FOR AXLE ALIGNMENT 2

Note
Some adjustment data for some axles was not available at the time of going to press!

General
The checking and setting values in this table provide a basis for the alignment and adjustment of
steered axles. Compliance with these is an essential precondition for driving and steering
properties and proper tyre running. The operating instructions of the equipment manufacturer are
to be followed for optical axle alignment!

"The vehicle must stand unladen on its wheels during adjustment"

All values are given in angular degrees (°) or angular minutes (‘) (1° = 60’). If the track is measured
in mm, the associated dimension can be taken from the conversion table as the particular
reference diameter (diameter of the wheel at the point at which the track dimension is taken).
Equally, the same procedure is to be used for axle alignment instruments that measure the track
in mm per m.

Angular minutes to mm conversion table

Diameter Corresponds to rim measured at rim flange Track in mm for 5 angular minutes

300 0.4

350 0.5

400 16.0 inch 0.6

450 17.5 inch 0.7

500 19.5 inch 0.7

550 20.0 inch 0.8

600 22.5 inch 0.9

650 24.5 inch 1.0

700 24.0 inch 1.0

750 1.1

800 1.2
850 1.2

900 1.3

950 1.4

1000 1.5

1050 1.5

1100 1.6
1150 1.7

1200 1.8

1250 1.8

2 – 25
AXLE ALIGNMENT

Diameter Corresponds to rim measured at rim flange Track in mm for 5 angular minutes

1300 1.9

1350 2.0
1400 2.0

The track dimension in mm depends on the point at which the measurement is taken. This is normally the rim
flange. In order, however, to enable the measurement to be taken at any point, track dimensions for a track
of 0°5’ are given for rims or brake drum or tyre diameters of 300 to 1400 mm.

During track adjustment make sure the screw in depth of the track rod end is correct! (See following drawing)

Correct: a = b

Track rod with fine adjustment

Visible thread length "a" must be approximately equal to the visible thread length "b".

Track rods without fine adjustment

The permissible difference (1) between the left and right side is a maximum of 4 mm

Tightening torques for track rod clamp fitting (screw/nut)

Thread size Straight track rod 8.8/ w.w.10.9/10 Track rod with fine adjustment 10.9/10
10.9/10

M10x1 50 Nm

M12x1.5 80 Nm 120 Nm

M14x1.5 170 Nm

2 – 26
 AXLE ALIGNMENT

CHECKING AND SETTING VALUES FOR AXLE ALIGNMENT 2

Track
CAUTION
Before the starting the toe-in adjustment, the steering box must be in the central position. The
marks on the steering box and spindle must be aligned. Any adjustment necessary must always
be made on the "pushrod".

Type of vehicle Track

Truck (measured using angle measuring 0°5’ to 0°10’

instrument)

Bus (measured using angle measuring 0° to 0°10’

instrument)

Wheel camber

Axle type Wheel camber

All axles (not adjustable) 1°

Kingpin inclination

Axle type Kingpin inclination

All axles (not adjustable) 7°

Toe-difference angle

Axle type Steer angle Steer angle Toe-difference angle

(wheel on inside of (wheel on outside of
curve) curve)

VOK-08/VOK-09 20° 17° 26’ 2° 34’

VO-09 20° 17° 34’ 2° 26’

LOL-08/NOL-08 20° - -

VOK-06-B 20° 18° 08’ 1° 52’

VOK-07-B 20° 18° 08’ 1° 52’

VOK-07-F 20° 18° 0’ 1° 52’

NOL-06-B 20° - -

Castor
CAUTION
The castor values apply for main frame position 0°. If the measured castor value is compared with
the desired value in the table, the frame inclination must be added to the measured value if the
frame inclination is forward.
It is subtracted if the frame inclination is rearwards.
The castor values are guide values. Depending on the operating conditions, it may be necessary
to set the castor individually within the tolerance limits.

Type of vehicle Castor

All 3°

2 – 27
 FRONT AXLE

FRONT AXLE 3

(1) Front axle

(2) Shock absorber
(3) Brake caliper
(4) Brake disk

3 – 29
 FRONT AXLE

REMOVING AND REFITTING FRONT AXLE 3

Includes:
• Tilting the cab (Operator's Manual)
• Removal of front skirt (RA cab)

(1) Front axle

(2) Shock absorber
(3) Brake caliper
(4) Brake disk

Technical data
Self locking nuts for spring clip ............................................................................................................ 330 Nm
Shock absorber bottom mounting ........................................................................................................ 400 Nm
Enco self-locking nut on steering lever ................................................................................................ 315 Nm

Notes
Note
The removal and refitting of a VOK-08-03 front axle with spring suspension is described here as
an example.

CAUTION
When jacking the vehicle, place supporting blocks at the front out as far as possible on the frame
extensions or cross member.
Renew all self-locking threaded elements.

3 – 31
FRONT AXLE

Special tools

[68] Hydraulic pump ........................................................................80.99620-6008

in conjunction with serial numbers [522] and [523]

• Press out the steering pushrod joint

[522] Flat cylinder ..............................................................................80.99601-6015

in conjunction with (68) and [523]

• Press out the steering pushrod joint

[523] Ball joint extractor .....................................................................80.99601-6005

when used hydraulically in conjunction with [68] and [522]

• Press out the steering pushrod joint (hydraulic/mechanical)

3 – 32
 FRONT AXLE

REMOVING AND REFITTING FRONT AXLE 3

Remove

Remove left and right brake-pad wear sensors (1)

Position supporting plate (1) with jack under front
axle and lash down
Raise the vehicle at the front axle (2)

Unscrew left and right ABS sensors (1)

Jack up the vehicle at the front outside on the cross

member (1) (not in the centre)
Remove the wheels (Operator's Manual)

Unbolt left and right shock absorbers (1)

Unscrew the pneumatic pipe (1) from the left and

right diaphragm cylinders

3 – 33
FRONT AXLE

Remove the ball joint using mechanical force

Unscrew pushrod castellated nut (1)

Using a ball joint extractor (1) [523], press the
steering pushrod joint out of the steering lever (2).
Remove the ball joint using hydraulic force
CAUTION
Make sure the ball joint separator is not
tilted.

To position the extractor, open the locking ring of the

ball joint and push the pad downwards. Using a ball
joint separator (1) [68], [522] and [523], press the
steering pushrod joint out of the steering lever (2).

CAUTION Unbolt left and right shock absorbers (1)

Make sure the ball joint extractor is not
tilted.

Unbolt left and right stabilizer (1) mounting

3 – 34
 FRONT AXLE

Lower and remove front axle (1)

Refit

Position the front axle under the vehicle and raise it

carefully
Insert left and right spring plates (2) into guide
pins (1)
Fit front axle
Torque tighten bolts/nuts to the specified tightening
torque

3 – 35
 WHEEL HUB ASSEMBLY

WHEEL HUB ASSEMBLY 4

(1) Hub unit bearing

(2) Thrust washer
(3) Slotted nut
(4) Brake disk
(5) Wheel flange

4 – 37
 WHEEL HUB ASSEMBLY

REMOVING AND REFITTING BRAKE DISK 4

Includes:
• Removing and refitting brake calliper (RA P 106)

(1) Brake disk

(2) Wheel flange
(3) Allen bolt, wheel hub to brake disk
(4) Mounting bolts, wheel hub to brake disk and hub unit bearing

Technical data
Mounting bolts, wheel hub to brake disk and hub unit bearing ............................................................ 430 Nm
Allen bolt, wheel hub to brake disk ........................................................................................................ 80 Nm

Notes
Note
If the brake disk cannot be pushed out using the extractor bolts, it can be hydraulically extracted.

CAUTION
Check the greasing of the hub unit bearing when changing a brake disk.
If there is defect in the brake system, such as overheated brakes, it is generally necessary to
replace the bearings.

CAUTION
If there are spacers between the brake disk and wheel flange, they are to be discarded.
A wider wheel flange part No. 81.44301-0185 is fitted instead (Si 78503).
The aforementioned wheel flange must be fitted to both sides!

4 – 39
WHEEL HUB ASSEMBLY

Special tools

[1] Extractor bolts...........................................................................06.01734-4320

• Extracting brake disk

[430] Lifting hook ...............................................................................80.99629-0031

• Removing and refitting brake disk

[68] Hydraulic pump.........................................................................80.99620-6008

In conjunction with serial No. [440], [548], [549], [550], [551] and [552]

• Extracting brake disk

[440] 200 KN hollow piston cylinder ..................................................80.99601-6014

In conjunction with serial No. [68], [548], [549], [550], [551] and [552]

• Extracting brake disk

[552] Pressure piece for 200 KN .......................................................80.99601-0193

In conjunction with serial No. [68], [440], [548], [549], [550] and [551]

• Extracting brake disk

[551] Extractor flange ........................................................................80.99601-0195

In conjunction with serial No. [68], [440], [548], [549], [550] and [552]

• Extracting brake disk

[548] Traverse ...................................................................................80.99601-0196

In conjunction with serial No. [68], [440], [549], [550], [551] and [552]

• Extracting brake disk

4 – 40
 WHEEL HUB ASSEMBLY

[550] Two threaded rods M20x270 ................................................... 80.99601-0194

In conjunction with serial No. [68], [440], [548], [549], [551] and [552]

• Extracting brake disk

[549] Two M20 collar nuts ................................................................. 80.99601-0197

In conjunction with serial No. [68], [440], [548], [550], [551] and [552]

• Extracting brake disk

4 – 41
WHEEL HUB ASSEMBLY

REMOVING AND REFITTING BRAKE DISK 4

Remove brake disk Remove brake disk using extractor bolts

Remove wheel flange

Insert extractor bolts into brake disk (1) [1] and

press out brake disk
Unscrew wheel flange mounting bolts (1) and Allen
screw (2)

CAUTION
The brake disk and wheel flange are
heavy. Danger of injury from falling brake
disk or wheel flange

Lift off the brake disk using the lifting hook [430]
hooked in at the back and extractor bolts screwed in
at the front

Remove wheel flange

4 – 42
 WHEEL HUB ASSEMBLY

Remove brake disk using hydraulic force

Connect the hydraulic pump (1) [68] to the hollow

Attach extractor flange (1) [551] by three bolts (2) to piston cylinder (2)
the brake disk
Secure the brake disk and wheel hub by means of a
lifting strap (3)

Using the hydraulic extractor, extract the brake disk

from the hub unit bearing and then place on the
ground using a crane
Insert the pressure piece (2) [552] into the hollow
piston cylinder (1) [440]
Insert the hollow piston cylinder into the extractor
flange (3)

Assemble the threaded rods (1) [550], collar nuts (2)

[549] and traverse (3) [548] and screw the assembly
into the (4)

4 – 43
WHEEL HUB ASSEMBLY

Fit brake disk Removing and refitting ABS speed sensor

Grease the central collar (contact faces) of the Remove clamping sleeve (1)
brake disk and wheel hub with high-temperature Withdraw speed sensor (2)
grease. With the lifting hook hooked in at the back Grease the clamping sleeve (1) with high-
and the extractor bolts screwed in to the front, place temperature grease and push it fully home (do not
the brake disk on the bearing unit (wheel hub). strike) until it lies against the pulse generator wheel,
Remove the extractor bolts and adjust the hole while rotating the wheel hub two to three times.
circle relative to the bearing unit. The necessary clearance is set up automatically.

Place the wheel flange in position and adjust to the

hole circle

Tighten the mounting bolts (1) diagonally,

fit Allen bolt (2) and torque tighten to the specified
tightening torque

4 – 44
 WHEEL HUB ASSEMBLY

CHECKING HUB UNIT BEARING FOR WEAR 4

(1) Dial gauge

(2) Track-rod arm
(3) Brake disk

Technical data
End float....................................................................................................................................... max. 0.2 mm
(corresponds to a wheel tilt movement of 0.25 mm)

Notes
Note
If there is an indication of a malfunction of the hub unit bearing, a check for wear as follows is
recommended:

• End float measurement

• Check for noise
• Functioning of sealing system (leakage of grease)

4 – 45
WHEEL HUB ASSEMBLY

CHECK FOR WEAR 4

Measurement of end float Increased grease leakage

Raise the wheel Remove the wheel and wheel flange

Place the magnetic support (1) with the dial gauge If the complete inside space, e.g. inside of the wheel
under the brake disk at the bottom making sure it is flange axle nut is covered in grease, a leakage of
not tilted grease has taken place. In this case, the hub unit is
Position the probe (2) against the front track lever to be renewed. This is mainly accompanied by
bolt and align vertically relative to the brake disk strong discolouration (blue) of the flange.
Tilt the wheel by pushing and pulling alternately and
read the travel shown on the dial gauge CAUTION
The wear limit is 0.25 mm tilt movement There may be a small amount of grease
(corresponds to a hub unit bearing end float of on the bottom edge of the seal. This is a
0.2 mm) normal occurrence and does not indicate
a leakage of grease.

Check for noise

Raise the wheel
Rotate wheel in both directions
If the bearing seems rough and a grinding noise can
be heard, the hub unit bearing must be renewed

CAUTION
A ticking or clicking noise is normal
because despite being raised the bearing
is still under load and the rollers are
therefore not aligned and can thus move
in an axial direction.

4 – 46
 WHEEL HUB ASSEMBLY

REMOVING AND REFITTING HUB UNIT BEARING 4

Includes:
• Removing and refitting brake calliper (RA P106)
• Removing and refitting brake disk, page 39

(1) Wheel flange

(2) Hub unit bearing
(3) Thrust washer
(4) Slotted nut

Technical data
Slotted nut for hub unit bearing............................................................................................................ 740 Nm

Consumables
Molykote Paste D lubricant ....................................................................................................... 09.15011.0001

Notes
Note
If it mechanical extraction of the hub unit bearing is not possible it can be extracted using
hydraulic force.

CAUTION
Use only Molykote paste when fitting the wheel bearing.
Renew self-locking number of the hub unit wheel bearing.

CAUTION
When tightening the slotted nut, the outer bearing ring must also rotate with it!

4 – 47
WHEEL HUB ASSEMBLY

Special tools

[60] Spindle......................................................................................80.99606-0240

• Removing and refitting wheel hub

[61] T-handle....................................................................................80.99606-0241
part of [60]

• Removing and refitting wheel hub

[84] Extractor cover .........................................................................80.99606-0238

basic unit [131]

• Unscrewing the wheel hub

[129] Extractor cover .........................................................................80.99606-0239

part of [72] 80.99606-6001

• Tightening the wheel hub

[130] Threaded bush .........................................................................80.99606-0251

• Removing and refitting wheel hub

[350] Slotted nut socket .....................................................................80.99603-0253

in conjunction with [351, 352, 353]

• Undoing and tightening the slotted nut for the hub unit bearing

[351] Retaining flange........................................................................80.99606-0465

in conjunction with [350], [352], [353]

• Undoing and tightening the slotted nut for the hub unit bearing

4 – 48
 WHEEL HUB ASSEMBLY

[517] 4 hexagonal-head bolt M18x1.5x30......................................... 06.01733-4611

for retaining flange [351]

• Undoing and tightening the slotted nut for the hub unit bearing

[530] Retainer ................................................................................... 80.99622-0045

in conjunction with [351], [352], [353]

• Undoing and tightening the slotted nut for the hub unit bearing

[353] Force intensifier spanner ......................................................... 83.09195-6001

• Tightening the slotted nut for the hub unit bearing

[430] Lifting hook............................................................................... 80.99629-0031

• Removing and refitting brake disk

[432] Extractor flange........................................................................ 80.99604-0464

• Removing hub unit bearing

[519] Adapter .................................................................................... 80.99606-0463

• Fitting hub unit bearing

4 – 49
WHEEL HUB ASSEMBLY

REMOVING AND REFITTING HUB UNIT BEARING 4

Remove hub unit bearing retaining flange (2) [351], and in doing so slide it
over the slotted nut and bolt it to the retaining flange
Unscrew slotted nut

Using the special tool shown below, unscrew the Secure the retaining flange (2) [530] to the force
slotted nut (1) intensifying spanner (1) [353] and move it to its
rotation stop
Unscrew the slotted nut

Place the slotted nut spanner (1) [350] on the slotted

nut
Place the retaining flange (2) [351] over the slotted Remove the slotted (1) and thrust washer (2)
nut against the wheel hub and secure in place using
four bolts (3) [517]
-The retaining flange carries the slotted nut-

Place the force intensifying spanner (1) [353] on the

4 – 50
 WHEEL HUB ASSEMBLY

Extract bearing unit Fit the hub unit bearing

Fit the bearing unit

Using the following special tool, extract the hub unit

bearing
Secure the extractor flange (1) [423] to the wheel CAUTION
hub by four bolts [517] When fitting the hub unit bearing take not
Screw the threaded bush (2) [130] into the extractor to damage the ABS pulse generator
flange wheel.

Grease the axle stub and bearing wheel Molykote

paste D
Screw the extractor sleeve (1) [519] onto the hub
Slide the hub unit bearing into place and tighten as
necessary using the tool shown below

Screw the extractor cover (1) [84] into the threaded

bush
Screw the spindle (2) [60] into the extractor cover
Rotate the spindle to extract the wheel bearing

Secure the extractor flange (1) [432] to the hub unit

bearing using four bolts [517]
Screw the threaded bush (2) [130] into the flange
Screw the extractor cover (3) [129] into the threaded
bush
Screw the T-bar (4) [61] onto the spindle (5) [60]
Screw in the spindle and tighten the hub unit bearing
fully to its stop using the T-bar

Remove the wheel bearing

4 – 51
WHEEL HUB ASSEMBLY

Fit slotted nut

Place new slotted nut (1) in position and screw in

using the special tool and torque tighten as specified

CAUTION
When tightening the slotted nut, the outer
bearing ring must also rotate with it.

CAUTION
No further bearing adjustment necessary.
If a slotted nut has been undone it must
be renewed (self-locking).

4 – 52
 WHEEL HUB ASSEMBLY

REMOVE THE HUB UNIT BEARING USING HYDRAULIC FORCE 4

Includes:
• Removing and refitting brake calliper (RA P 106)
• Removing and refitting brake disk, page 39

Extractor for 200 KN Extractor for 750 KN

(1) Threaded rods [550] (7) Hollow piston cylinder [325] and
(2) Collar nuts [549] pressure piece [553]
(3) Traverse [548] (8) Extractor flange [551]
(4) Hollow piston cylinder [440] and pressure piece [552]
(5) Extractor flange [551]
(6) Hydraulic pump [68]

Notes
Note
Depending on the difficulty, the hub unit bearing is extracted using 220 KN or 750 KN

Special tools
[548] Traverse................................................................................... 80.99601-0196

• Removing hub unit bearing

[549] Two collar nuts ......................................................................... 80.99601-0197

• Removing hub unit bearing

[550] Two threaded rods M20x270 ................................................... 80.99601-0194

• Removing hub unit bearing

4 – 53
WHEEL HUB ASSEMBLY

[551] Extractor flange ........................................................................80.99601-0195

• Removing hub unit bearing

[552] Pressure piece for 200 KN .......................................................80.99601-0193

• Removing hub unit bearing

[553] Pressure piece for 750 KN .......................................................80.99601-0192

• Removing hub unit bearing

[440] 200 KN hollow piston cylinder ..................................................80.99601-6014

• Removing hub unit bearing

[325] Hydraulic press.........................................................................80.99606-6079

(for use with hollow piston cylinder only)

• Removing hub unit bearing

[68] Hydraulic pump.........................................................................80.99620-6008

• Removing hub unit bearing

4 – 54
 WHEEL HUB ASSEMBLY

REMOVE HUB UNIT BEARING USING HYDRAULIC FORCE 4

Extract the bearing unit using 200 KN

Connect the hydraulic pump (1) [68]

Using all the bolts (2), secure the extractor flange (1) Extract the bearing unit
[551] to the circumference of the hub unit bearing (3)

Extracting the bearing unit using 750 KN

Insert the pressure piece (2) [552] into the hollow

piston cylinder (1) [440] Insert the pressure piece (1) [553] into the hollow
piston cylinder (2) [325]
Insert the hollow piston cylinder into the extractor
flange (3) [551]

Insert the hollow piston cylinder (1) into the extractor

flange
Assemble the traverse (2) [548], threaded rods
[550] and collar nuts [549] together and screw into Fit the assembled extractor (1) on to the hub unit
the extractor flange bearing by means a crane (2)
Secure the hub unit bearing and extractor using a Attach the extractor to the circumference of the hub
lifting strap (3) unit bearing using all the bolts (3)

4 – 55
WHEEL HUB ASSEMBLY

Connect the hydraulic pump [68]

Withdraw the bearing unit (1) from the hub (2)

4 – 56
 STUB AXLE

STUB AXLE 5

(1) Radial shaft sealing ring

(2) Stub axle pin
(3) Needle bushing
(4) Round sealing rin
(5) Sealing washer
(6) Locking ring
(7) Grease nipple
(8) Sealing cap
(9) Stub axle
(10) Bottom needle bushing
(11) Shim(s)

5 – 57
 STUB AXLE

CHECKING END FLOAT OF STUB AXLE 5

(1) Probe on the bottom edge of the axle knuckle

(2) Track-rod arm
(3) Dial gauge holder on the track rod arm

Technical data
End float....................................................................................................................................... max. 0.4 mm

Notes
Note
If the end float is greater than 0.4 mm, remove the stub axle and renew all damaged parts.

Check end float

Secure the vehicle against rolling
Secure the dial gauge holder (3) to the track rod arm
Position the dial gauge so that the probe (1) is in contact with the centre of the free bottom edge of the axle
knuckle (the distance between the mounting of the holder and the probe of the dial gauge must be as small
as possible)
Raise the front axle, set dial gauge to zero
Lower the front axle
Measure the end float on the dial gauge

5 – 59
 STUB AXLE

REMOVING AND REFITTING AXLE KNUCKLE 5

Includes:
• Removing and refitting running wheels (Operator's Manual)
• Removing and refitting disk brakes (P106)
• Removing and refitting brake disk, page 39
• Removing and refitting hub unit bearing, page 47
• Removing and refitting track-rod joint, page 79

(1) Hub unit bearing (6) Top needle bushing

(2) Stub axle (7) Stub axle pin
(3) Sealing cap (8) End float
(4) Sealing washer (9) Shim(s)
(5) Sealing ring (10) Bottom needle bushing

Technical data
Settings
End float between stub and axle knuckle..................................................................................... max. 0.2 mm
(shims available in sizes 1.8 – 2.6 mm)

Consumables
DEA Renolit-OTP2 grease packing after assembly of stub axle bearing.................................. 09.15006.0018

Notes
CAUTION
After assembly of the stub axle bearing, apply DEA Renolit OTP2 to the lubrication points at high
pressure using a grease nipple connector

5 – 61
STUB AXLE

Special tools

[325] Hydraulic press 750 KN............................................................80.99606-6079

• Removing and refitting stub axle pin

[68] Hydraulic pump.........................................................................80.99620-6008

in conjunction with serial number [325]

• Removing and refitting stub axle pin

[317] Spacer sleeve ...........................................................................80.99604-0228

basic unit [131]

• Unscrewing the wheel hub

[313] Pressure mandrel .....................................................................80.99617-0183

• Extracting the stub axle pin

[315] Pressure mandrel .....................................................................80.99617.0179

• Fitting the stub axle pin

[314] Centring mandrel (without magnet) ..........................................80.99617-0196

• Centring the stub axle

[316] Centring mandrel, short (with magnet) .....................................80.99617-0197

• Fitting the stub axle pin

5 – 62
 STUB AXLE

[323] Pressure mandrel..................................................................... 80.99617-0195

• Pressing the sealing cap onto the axle bearing

[324] Assembly tongs...................................................................... 80.99625-60015

• Closing the bottom needle bushing

5 – 63
STUB AXLE

REMOVING AND REFITTING STUB AXLE 5

Remove stub axle

Position the hydraulic press (1) [325] and align with

Remove the sealing caps (1) at the top and bottom the axle stub (2)
of the stub axle Lash the axle stub using a lashing strap (3)
Connect the hydraulic pump [68] to the press

Remove the locking rings (1) from the top and

bottom Press the dust cover (1) of the needle bushing
downwards

Remove the sealing cap (2) and sealing ring (1) at

the top and bottom Insert the pressure mandrel (1) [313] underneath
the press
Fit the spacer sleeve (2) [317] at the top of the stub
axle
Press out the stub axle pin upwards from below
through the spacer sleeve (2)

5 – 64
 STUB AXLE

(The end float is greater than 0 and less than

0.2 mm)

Fit stub axle

Extract the stub axle pin (1) using a suitable centring

mandrel (2) (use of magnet)

(Raise the hydraulic cylinder of the press)

Centre the stub axle (1) in the press, using a
pressure mandrel (2) [315] and spacer sleeve (3)
[317]
Slide the stub axle over the axle knuckle, ensuring
shim (4) is fitted

Lower the press, remove the press mandrel (1)

[313] and replace it by press mandrel [315]
Raise the press and centre the stub axle (2)
between the spacer sleeve (3) [317] and pressure
mandrel (1)
Extract the stub axle from the axle knuckle

Set end float

Move the press to one side
Use a lifting strap/crane (1) to secure the stub axle
against falling
Using the centring mandrel (2) [314], centre the
bearing and shim of the stub axle

Measure dimension A of the stub axle space

Measure dimension B of the axle knuckle
Dimension B – dimension A is the end float
Set the end float using shim(s) (1)

5 – 65
STUB AXLE

Using the centring mandrel (2) [316] in the stub axle Fit the top and bottom sealing ring and the sealing
pin (1) into the axle bearing washer (1) and secure using locking ring (2)

Using high pressure, lubricate the stub axle pin from

both ends

CAUTION
Use only DEA Renolit OTP2 grease

Remove the lifting strap

Position the press and press the stub axle pin (1)
fully home using the pressure mandrel (2) [315]

Drive the sealing cap into place at both ends using

a mandrel (1) [323]
(Shown with brake calliper fitted)

Slide the dust cover of the needle bushing upwards

until it engages, using assembly tongs (1) [324]

CAUTION
Do not damage the dust cover

5 – 66
 STUB AXLE

REMOVING AND REFITTING STUB AXLE BEARING 5

Includes:
• Removing and refitting running wheels (Operator's Manual)
• Removing and refitting disk brakes (P106)
• Removing and refitting brake disk, page 39
• Removing and refitting hub unit bearing, page 47
• Removing and refitting track-rod joint, page 79
• Removing and refitting axle knuckle, page 61

Stub axle rotated 180° (1) Stub axle

(2) Extractor mandrel
(3) Bottom needle bushing
(4) Sealing ring of top needle bushing

Notes
CAUTION
Before transporting the axle stub, e.g. place to one side or rotate, always fit transport sleeve so
that bearing needles do not drop out

Special tools

[325] Hydraulic press 750 KN ........................................................... 80.99606-6079

• Removing and refitting stub axle pin

5 – 67
STUB AXLE

[68] Hydraulic pump.........................................................................80.99620-6008

in conjunction with serial number [325]

• Removing and refitting stub axle pin

[317] Spacer ......................................................................................80.99604-0228

basic unit [131]

• Unscrewing the wheel hub

[318] Spacer sleeve ...........................................................................80.99635-0051

• Removing top and bottom needle bushing sleeves

[319] Pressure mandrel .....................................................................80.99617.0190

• Fitting top and bottom needle bushing sleeves

[320] Pressure sleeve........................................................................80.99635-0050

• Fitting top needle bushing

[321] Pressure sleeve........................................................................80.99635-0049

• Fitting the stub axle pin

5 – 68
 STUB AXLE

REMOVING AND REFITTING STUB AXLE BEARING 5

Extract needle bushing Extract top needle bushing

(Move hydraulic cylinder of press downwards from Remove sealing ring (1) from the top needle
top) bushing
Rotate stub axles (2) by 180° and place on spacer
sleeve (1) [317] in the press
Lash the stub axle using lashing straps

Using a press mandrel (2) [319] and extractor bush

(1) [318], press out the top needle bushing

Fit extractor bush (1) [318] and press out the bottom
needle bushing (2)

5 – 69
STUB AXLE

Fit top needle bushing (Stub axle is now in the installation position)

CAUTION
Before transporting the axle stub, e.g.
place to one side or rotate, always fit
transport sleeve so that needle bearings
do not drop out

Remove the transport sleeve from the top needle

bushing (1)
Insert bush (2) [320] into the stub axle bore
Insert the extractor bush (3) [318] into the stub axle
bore as a guide sleeve
Press in the needle bushing fully home using
insertion mandrel (4) [319]
Insert insertion bush (2) [321] into the bottom needle
bushing (1) (transport sleeve remains in needle
Fit lower needle bushing bearing)
Insert both together into the stub axle bearing
Insertion the insert bush (3) [320] into the top
bearing as a guide sleeve
Using the pressure mandrel (4) [319], press the
needle bushing fully home

Remove both extracted needle bushing (1) and (2)

from the spacer sleeve (3)

Fit sealing ring (1) for the top needle bushing

CAUTION
Before fitting the stub axle, check the end
float between the stub axle and axle
knuckle and adjust as necessary

Rotate the stub axle (1) through 180° in the press to

fit the bottom needle bushing.

5 – 70
 STUB AXLE

REMOVING AND REFITTING AXLE END (LO, NO) 5

Includes:
• Removing and refitting running wheels (Operator's Manual)
• Removing and refitting disk brakes (P 106)
• Removing and refitting brake disk, page 39
• Removing and refitting hub unit bearing, page 47

(1) Axle end

(2) Axle tube
(3) Axle tube mounting bolt

Technical data
Mounting bolt, axle end
M22x1.5x70 ......................................................................................................................................... 680 Nm
M18x1.5x60 ......................................................................................................................................... 410 Nm

Remove
Remove mounting bolts (3)
Remove axle end (1)

Refit
Refit axle end and torque tighten the mounting bolts to the specified torque

5 – 71
 STEERING / TRACK-ROD ARMS AND TRACK-RODS

STEERING / TRACK-ROD ARMS AND TRACK-RODS 6

(1) Track-rod
(2) Track-rod arm
(3) Steering arm
(4) Stub axle
(5) Ball joint

6 – 73
 STEERING / TRACK-ROD ARMS AND TRACK-RODS

CHECK STEERING TRACK-ROD ARMS AND TRACK-RODS 6

(1) End float of ball joint

(2) Ball joint

Technical data
Permissible end float....................................................................................................................... max. 2 mm

6 – 75
STEERING / TRACK-ROD ARMS AND TRACK-RODS

CHECK STEERING TRACK-ROD ARMS AND TRACK-RODS 6

Check for wear

Note
For the test, the vehicle must be resting on its wheels.
Clean joints, sealing bellows and connecting parts.

Track-rod (1), clamp (2) or ball joint (4) may show no The clips of sealing bellows (5) must be present and
signs of the effects of force and must not be undamaged and correctly located in the grooves
corroded, abraded, bent or crushed or have any provided for the purpose. Manual rotation (do not
deep rust pitting (up to max. 1 mm depth permitted). use tools) of sealing bellows must not be possible.
Pay particular attention to the roll spot weld on the (Sealing bellows must not be damaged or cracked)
ball joint cover (3). To check, press or massage the bellows by hand.
(No grease shall emerge through the bellows wall)
The track-rod may sometimes have a slight barely
discernible buckle. It is therefore essential before CAUTION
adjusting the track to check, using a straight edge, Cracks in the sealing bellows result in the
that the track-rod is straight. If the track-rod is ingress of water, cause corrosion and
buckled, it must be replaced. thus to premature damage to the track-
rod joint.
CAUTION
If there are signs of force and/or
excessive stress, very carefully examine
the steering system, wheels, axle
mountings etc.

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 STEERING / TRACK-ROD ARMS AND TRACK-RODS

Check of end float

Tyre lever

To check the end float of the ball joint, move the Additional check on track-rods with fine adjust-
wheels backwards and forwards from the centre ment
position and at the same time check the ball joint (2)
and track-rod tube. Correct: a = b
The max. end float of the ball joint is 2.0 mm
(wear limit)
Absolutely no play may occur when manually pulling
and pushing
Rotate the track-rod radially by hand (do not use a
tool).

Note
If the track-rod cannot be rotated by
hand, a ball joint may be corroded
corroded. Rust in the ball joint can cause
the end float to appear correct when it is
not. An inspection of the track-rod in
conjunction with an inspection of the The visible thread length (a) of the ball joint must be
sealing bellows (5) is particularly exactly the same length as the visible thread length
important. (b) of the adjusting sleeve.
If it is not, the track-rod must be re-adjusted.
Note
To facilitate checking of the end float, use
a tyre lever (3) to lever against the ball
joint (minimum leverage ratio 1:2
between the tyre lever support and the
force F acting on the ball joint) and
measure the play with a feeler gauge.

There shall be no backlash in the adjusting thread

(4) of the ball joint end.

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 STEERING / TRACK-ROD ARMS AND TRACK-RODS

REMOVING AND REFITTING TRACK-ROD JOINT 6

Includes:
• For checking/setting the track see Checking and setting values for axle alignment, page 25

(1) Track-rod
(2) Track-rod joint
(3) Track-rod arm
(4) Sliding block (spare part number 81.36304.0017)
(5) Ball joint extractor, hydraulic

Technical data
Track-rod clamp, M14x1.5 ................................................................................................................... 170 Nm
Track-rod clamp M12x1.5 ...................................................................................................................... 80 Nm
Self-locking nut of track-rod joint on track-rod arm .............................................................................. 300 Nm

Notes
CAUTION
Make sure the ball joint extractor is positioned without tilting.
Renew all self-locking threaded elements.

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STEERING / TRACK-ROD ARMS AND TRACK-RODS

Special tools

[68] Hydraulic pump.........................................................................80.99620-6008

in conjunction with serial numbers [522] and [523]

• Separating the track-rod joint

[522] Flat cylinder ..............................................................................80.99601-6015

in conjunction with (68) and [523]

• Separating the track-rod joint

[523] Ball joint separator ....................................................................80.99601-6005

when used hydraulically in conjunction with [68] and [522]

• Separating the track-rod joint

(hydraulic/mechanical)

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 STEERING / TRACK-ROD ARMS AND TRACK-RODS

REMOVING AND REFITTING TRACK-ROD JOINT 6

Remove Track-rod joint, remove using hydraulic force

Remove self-locking nut (1) from track-rod end Place sliding block (spare part number
81.36304-0017) between the piston (1) of the
cylinder and the track-rod joint
Using a ball joint extractor (2) [68], [522] and [523],
mechanically press out the track-rod joint from the
track-rod arm

CAUTION
Make sure the ball joint extractor is not
tilted when positioned!

Track rod joint, remove using mechanical force

Open the locking clip (1) and press the rubber

sleeve downwards
(This is necessary to enable the extractor to be
fitted)

Using a ball joint extractor (1) [523], press out the

track-rod joint from the track-rod arm

CAUTION
Make sure the ball joint extractor is not
tilted when positioned!

Press out the second track-rod end and remove the

track rod

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STEERING / TRACK-ROD ARMS AND TRACK-RODS

Slacken clamp (1)

Hold the intermediate sleeve on the hexagon (2)
Unscrew the track-rod joint (3) from the track rod

Fit track-rod joint

Screw the track-rod adjusting sleeve fully in

Screw the track-rod end(s) fully in
Fit track-rod:
Position the left and right track-rod joint (1) on the
track-rod arm (2) and press in the taper
Fit new self-locking nuts, using an Allen key (3) as
necessary to prevent turning
Tighten the nuts to the specified torque

CAUTION
Renew self-locking threaded elements

Check/adjust the toe-in, see Checking and setting

values for axle alignment, page 25

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 STEERING / TRACK-ROD ARMS AND TRACK-RODS

REMOVING AND REFITTING STEERING AND TRACK ROD ARMS 6

Includes:
• Removing and refitting track-rod joint, page 79

(1) Track rod arm

(2) Steering arm
(3) Stub axle
(4) Mounting bolts (Innentorx)

Technical data
Mounting bolts...................................................................................................................................... 680 Nm
(final tightening torque still not decided at time of going to press)

Notes
CAUTION
Damaged parts may not be straightened, fit new parts

Special tools

[543] IMP socket-T100 SW 22 .......................................................... 80.99603-6017

• Fitting and removing track-rod and steering arms

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STEERING / TRACK-ROD ARMS AND TRACK-RODS

REMOVING AND REFITTING STEERING AND TRACK ROD ARMS 6

Remove

Unscrew self-locking mounting bolts from the track-

rod arm using IMP socket (1)
Remove the steering and track-rod arms
Inspect the steering and track-rod arms for
deformation and cracking

Installation

Place steering (2) and track-rod (1) arms in position

Fit mounting bolts and torque tighten to the specified
torque

6 – 84