Mew SERVICE : Vehicle Type: DR RANGE Subject’ GENERAL THE MANUAL VEHICLE AREAS ‘This Manual is intended to describe the design of the Metrobus double deck public service vehicle manufactured by Metro Cammell Weymann Lid.,to instruct in its ‘maintenance and repair and to inform the operator of| design changes which may become necessary. For this purpose, the vehicle is divided into twenty two design arees (called Groups") each dealing with a separate, identifiable function of the design. These twenty ‘two Groups ate listed on the front reference card of the Manual in numerical order, each Group is separated and identified by a divider in the binder, also in numerical order. In such complex vehicle design, the interface between the various systems and components can be described as clastic, depending on how the observer sees it. Generally, ‘this Manual deals with the various separate functions of {an otherwise comprehensive system. For example, on an hydraulically braked vehicle, Group 22, Brake Operating Gear, the Manual deals with that part of the braking function, from the pedal to actuator, with no more then 8a cross reference to other functions of the integrated hydraulic system such as Steering and Engine Cooting. This epprozch allows a simplified explanation of what happens between a foot pedal and a brake actuator. The schematic drawings illustrating this must not be takon to represent anything more than one part of an incomplete system. The complote hydraulic system will be found in Group 0, General. Routine inspections and the diagnosis cof hydraulic faults must be conducted with this relation- ship of braking, steering and engine cooling in mind. Funetions served by the pneumatic generating and storage system are similarly separated. ‘The exception to this breakdown in Group 28, Electrical which describes the whole electrical system, Generally, where thare is an electrical service to a mechanical, hydraulic or pneumatic function, e.g. a warning or safety device, that Group only notes the existence of the device and under what conditions it operates. The wiring and switches which activate the device will be described in Group 28. Technical Descript LAYOUT OF TEXT Each of the twenty two groups in the Manual is broken down into four Headings: ‘Technical Description which covers the design concept of a function or component, describing its purpose in the vehicle and how it operates. Repair which covers all aspects of system and component maintenance, inspection, repair and test. ‘Specifications which summarises all system, and compon- ent pressures, torque values end other technical data, ‘Special Information which will be used to advise the ‘operator of all service bulletins issued by the Company. At the Company's discretion, this special information wil ‘be absorbed into the three main headings when the Manual, (or part of it, is reprinted, To assist identification of these Headings within a section, each right pege of the Manual has a black ‘marker on the right hand edge visible when the Manual is closed. The position of these markers is shown and identified on the Contents Lists of all Groups.frei MGM SERVICE Section 0 wae Subject! GENERAL Vehicle Type: DR RANGE CONTENTS LIST Each of these four Headings is further divided into Sections. ‘The number and content of Sections within a Group depends upon the complexity and scope of that Group. The contents list for each Group shows what each Heading contains: — Gop Strom ee airtrance and Rowton sks ‘Sign wes Aetarer Switches nd Sra Pal Adjustments Fe Bh Ac 8 ag Bal ‘igneous Units craton Fault Dignoss ‘and it will be seen that if @ component is first described in Technical Description, Section 1, it will later be treated in Repair, Section 1, for maintenance and servicing, and in Specifications, Section 1, for tachnical summary, This tee Previous ius 1 SEPTFMRER 1080Meu SERVICE fei Vehicle Type DR RANGE Subject! GENERAL VARIANTS: ‘At the front of each Group in the Manual will be found ‘the “Front Sheet” which gives the Group No. and Title, together with variants on the basic vehicle design, e.g ‘The vehicle is offered to operators with the option of either Hydraulic or Preumatic Brake Operating Cover: ‘The complete Manual will contain Group 222 (Hydraulic) ‘and Group 22(b} Pneumatic) but an operstor who orders ‘an hydraulically braked bus will receive Group 22a) in his copy of the Manual, while an operator ordering a ily braked bus will receive Group 22(b).. Technical Descriptic ‘The various sub groups are stated in the relevant Group, front sheet. Where an Option causes a minor change in a System common to both variants, this change is indicated in the System text and a Sub-Group is not created, e.g, Group 22 a, Repair, Section 4, page 2, Fig. 1 illustrates the only difference in the Brake Operating Gear (Hydraulics) between a Gardner and a Rolls Royce engined Variant, Sub Group a BRAKE OPERATING GEAR b Pneumatic Controls FEMI SERVICE Group Hydraulic ControlsGroup FRONT AXLE UME SERVICEMcuwt! SERVICE ‘Vehicle Type: DR RANGE Subject! FRONT AXLE Grow 18 Section 0, Contents List twain | Secvon | Page Nomar Sub oo wy R se 8 0 1 1 vfa 2 2 4 4 1 1 2 aya 2 2 2 4 4 5 6 6 1 1 3 fel 3 3 4 4 General Brake Assemblies Dismantling Inspection Assembly Fitting and adjusting Steck Adjusters Tightening torques — see Sections 2 & 3, Specifications Lubrication Stub Axle Assembly To remove the stub axle assy. Inspection To assemble swivel ‘Swivel adjustment Re-assembly To remove & dismantle ball socket asty. To assemble ball socket Check front whee! alignment Tightening torques Lubrication Front Axle Hub Assembly Dismantling Inspection Assembly Adjustment of end float Tightening torques Lubrication ‘Technical Description Specifications Repair aT SESE ae Be aed Special InformationWG SERVICE Grou 18 Vehicle Type: DR RANGE Section 0. Subject: FRONT AXLE Technical Descriptic GENERAL ‘The front axle is a modified $62 Kirkstall beam axle with {50 degree back lock angle, ‘The axle is equipped with stub axles carried on parallel king pins. Brakes are Kirkstall supplied and are provided with SAB automatic adjusters. The brake drums, constructed of special alloy cast iron, are carried on the outside of the hhub flanges. Design of the brakes permits brake servicing ‘without disturbing the hub, The steering ball joints have case hardened balls and rubbing pads incorporating compression springs which automatically compensate for wear. ‘Stock edjutort Axle bed Tie rod Fig. 1 Front axle Brake setuator bracket Brake drumUG SERVICE ie ‘Vehicle Type: DR RANGE eee Subject:, FRONT AXLE Technical Descriptio BRAKES ‘The brakes are Kirkstall designed 15%4"" x 8"”S — Cam ‘operated drum brakes fitted with SAB automatie slack adjusters. Holes provided in the hub permit brake shoe pivot pins and brake shoes to be removed with the hub in place, after removal of the brake drums, Brake shee tiner Brake shoe Brake shoe roller Brake bracket Fig. 1 Brake assembly Previous Issue ‘This sueTGW SERVICE isa Vehicle Type DR RANGE banish ‘Subject! FRONT AXLE Technical Descriptio STUB AXLE Each stub axle is carried on a parallel king pin, with » steep ‘angle taper roller bearing at the top and a plain Phosphor Wheel nut Bronze bush at the bottom,Wtf SERVICE mile ‘Vehicle Type: DR RANGE eit Subct! FRONT AXLE Technical Descriptio: FRONT AXLE HUB ‘The hub assembly is located on the stub axle being carried fon two taper rollor bearings. The assembly is secured by 2 special split unit, clamped by 3 pinch bolt, and washer which permits adjustment. Fig. 1 Stub axle assembly ‘This lave Peoe.SCM SERVICE ane Vebiele Type: DR RANGE beeealeat subject! FRONT AXLE Repair BRAKE ASSEMBLIES Pa ye a 6. Brake Drum 7, Hub Beering Nut 8. Bearing Nut Pinch Bolt 8. Bearing Nut Pinch Bolt Nut Key to Fig. 1 10. Hub Bearing Wesher 11. Hub cap Join 1. Hub cap 12, Hub Bearing Cone (Outer) Cup 2. Hub Cap Setscrens 13. Hub 3. Hub Cap Washor 14, Wheel Stud RLM. & LH, 4 Brake Drum Retaining Sow 15. Hub Bearing Cone & Cup (Inner) 5. Wheel Nut RAH. & LH 16. Hub OW Seal Fig. 1 Brake Drum Assembly 15 “Tool PartNo. 6651464 Fig, 2. Relieving Shoe Return Spring Tension Prviou lve ‘This tue PoseGroup 18 TEM SERVICE en Vehicle Type! DR RANGE Subject’ FRONT AXLE BRAKE ASSEMBLIES Remove the nuts (22) and washers (23) also bolts (25) Dismantling Brakes To remove the brake drums: 1. Jack up the vehicle and remove the road wheels, 2. Back off the brake adjustment. 3. Remove the brake drum retaining setscrews, Fig. 1 (4). 4, Support the brake drum, Fig. 1 (6), with a rope sling and pull the drum from the wheel studs, Dismantling the Front Brakes Note: Holes are provided in the hub to allow the brake shoe pivot pins,and the shoes themselves, to be removed with hub in place. For this operation the brake drums must be taken off Special tools required: Tool No. X6651464 for removing brake shoe return spring. Procedure: (Unless stated otherwise, drawing references are for Fig. 3). Using tool X6651464, as shown in Fig. 2, relieve the tension of spring (15) and pull out the anchor pins (13). A wire hook ‘can be inserted through the holes in the pins for easy removal. Remove the return spring (1), Remove the locknuts (11) and setscrews (10) securing the brake shoe pivot pins and remove the brake shoes. Disconnact the slack adjuster lever (27) from the air chamber push rod. Remove the citclip (31), washer (30), spring (28) and inner washer (28) from the camshaft (18). ‘The slack adjuster (27) can now be removed from the camshaft. Take off the brake chamber bracket nuts (37) and remove the chamber bracket (36). The bush (21) and ‘O' ring can be driven from the bracket. Withdraw the camshaft (18) along with its head washer (19) and 0" ring {20) from the brake bracket, When the camshafts have been removed they should be marked to ensure that they are replaced Cn the same side of the axle from which they have boon romoved. This tue securing brake bracket (12) to the swivel, and pull off the brackets. Drive out bushes (21) and oil seals (26). Inspection: ‘After carefully cleaning the various parts they should be inspected for weer and renewed if necessary. A light smear Of grease should be given to the pivot pins, oll seals and bushes before re-assembly Key to Fig. 3 1 2 3. 4 5 8. 7. 8, a Brake Shoe Assembly Brake Shoe Liner Brake Shoe Liner Rivet Brake Shoe Bush Brake Shoe Roller Brake Shoe Roller Pin Brake Shoe Roller Split Pin Brake Shoe Pivot Pin Brake Shoe Pivot Pin Setscrew Brake Shoe Pivot Pin Setscrew Brake Shoe Pivot Pin Locknut Brake Bracket LH, Return spring anchor pin Brake Shoe Anchor Pin Sp.Pin. Brake Shoe Return Spring Brake Anchor Pin (Brake Bracket) Brake Anchor Pin Spring Washer Brake Cam A.M. & LH, Brake Head Washer Brake Cam “O" Ring Brake Bracket Bush Brake Bracket Nut Brake Bracket Spring Washer Brake Bracket Stud Brake Bracket Bott Brake Cam Oil Collector Slack Adjuster Slack Adjuster, innor washer Brake Cam Spring Brake Cam End Washer Brake Cam Circlip Brake Shoe Pivot Pin Washer Not used Not used Not used Chamber Bracket Chamber Bracket Nuts Chamber Brackat Stud‘Vehicle Type DR RANGE ia ‘Subject, FRONT AXLE Repair | SGM SERVICE aoe Fig. 3 Brake assembly Previous ius “This tau PageGrou 18 Mew SERVICE Caamauiii Vehicle Type: DR RANGE subjects FRONT AXLE Repair Assambly of Brake Tools required: 6651404 for fitting brake shoe return spring X6651485 for fitting brake cam bush X6651466 — for fitting brake shoe bush 6651467 — bumper handle for X6651465 & X6651468 Fit new bushes (21) and oil seals (26) into the brake brackets (12). Fit brake bracket (12) to swivel, Secure with nuts (22) washers (23) and bolts (25) and tighten, Fit new ‘O' ring (20) and bush (21) into the chamber bracket/camshaft boss (96). Slide camshaft head washer (19) and ‘0’ ring (20) onto ‘camshaft (18). Re-fit the camshafts ensuring that they ere replaced at the same side as thay were removed. Refit bushes (4) into the brake shoes (1) and peen over in three equi-spaced positions as indicated in Fig. 4, Locate the roller (6) in position, fit the roller pin (6) so ‘that the headed portion will be towards the brake bracket when fitted and secure in place with split pin (7). Splay the split pin (7) to approx: 30° as shown in Fig. 5 to avoid fracture of leg Position the brake shoes (1) onto the bracket (12) and drive home the pins (8) ensuring that the flats align with the locking screw holes in the bracket, Fit locking screws (10) and lock ut (11). ‘Seat the rollers in position on the camshaft so that they lie in the depressions. See Fig. 6. This ensures that the cam is in its correct operating position, the brake shoe return spring (1) with the aid of tool 6651464 the springs can be extended whilst the retaining pin (13) is repositioned. (Fig. 7), Fit the slack adjuster (27) to tho camshaft splines end adjust. ‘the washer (28) spring (29) washer (30) and circlin (31), Fit the brake drum and secure with the countersunk serews, Connect the linkage between the air chamber and slack adjust Note: See Specifications, Sections 2 & 3 for torque tightening values. Fitting and Adjusting SAB Slack Adjuster Fit SAB Slack Adjuster (Fig. 3item 27) to the camshaft (Fig. 3 item 18) ensuring that the arrovr, on the adjuster ‘arm, points in the direction of brake application, Ensure that brake actuator piston push rod is fully retracted into breke cylinder. Using @ 12mm spanner on the slack adjuster adjusting hexagon, ‘align the hole in the adjuster control arm with the hole in the piston rod clevis. Fit elevis pin without moving piston rod or slack adjuster control arm, Push adjuster control arm as far as it will go in the direction of brake application, ‘When in this position secure to the anchor bracket with the bolt. Refit brake drums and secure with four setserews. ‘Manually adjust the brakes, with a 12mm spanner on the slack adjuster adjusting hexegon to give correct running clearance of 0.025" (0,635 mm),cu SERVICE ee Vehicle Type DR RANGE ‘Subject! FRONT AXLE Fig. 4 Securing bushes _snaKe SHOE Fig. 5. Scouring roller Fig. 7 Fitting brake shoe return spring [PeerSGM! SERVICE finite Vehicle Type: DR RANGE eat ‘Subject! FRONT AXLE Repair STUB AXLE ASSEMBLY Pace18 Broup im ii SERVICE Section 2 Subject). FRONT AXLE Vehicle Type: DR RANGE To remove the stub axle assembly, (refer to Fig. 1): Disconnect the steering levers (48 & 59) from the steering (gear and track rods. Remove the swivel top cap setscrews (18) and washers (19), ‘enabling the top cap (20) and joint (21) to be lifted off. Remove the setscrews (37) and washers (36) securing the ‘bottom cap (35) and pull off the cap and ‘0 ring (34). ‘Take out the split pin (23) and remove the swivel pin nut (22) and washer (24), Remove the cotter pin nut (54) and washer (55) and drive ‘out the cotter pin (53) from the axle beam (56). Give the axle beam (56) a sharp tap to loosen the swivel pin (33). The pin can then be driven out downwards, thus releasing the swivel assembly from the axle beam: The swivel assembly, complete with cylinder bracket and steering levers can then be pulled from the axle beam. ‘Take out the swivel bearings (25), bearing shims (26), bearing sleeve (27) and fett washer (28) from the swivel top. and felt washer (31), retaining ring (30) and bush (32) from the swivel bottom, Remove the lockwire (47), unscrew the nuts (46) and pull Off the brake actuator bracket (46) taking care not to darnage the studs (44). Take out the lockwire (62), remove nuts (61) and pull off the bottom lever (9) taking care not to damage the studs (57 & 58). Inspection: ‘Thoroughly clean all parts and inspect for wear, renewing if necessary. Inspect the steering arms for flaws which may have developed due to impact shocks. If distortion of the axle beam, swivel or steering levers has ‘occurred, it is impracticable to straighten without the ‘manufacturing facilities. Pack bearings with grease as stated in the specification section prior to reassembly. Repair To assemble swivel (refer to Fig. 1): Assemble the upper felt washer (28) and bearing sleave together and fit in position in swivel, ie. with felt to bottom and flush with top Inner face of swivel. Fit the upper bearing cup into top swivel bore, Press the bottom bush (32} into position in swivel, with the bush flush with the'lower inner face of swivel. Assemble the retaining ring (30) and felt washer (31) ‘together, place in position in swivel and offer the assembly to the axle beam (56), retaining in position, Drive the swivel pin (33) through the swivel (28) and axle ‘beam (56), ensuring that the machined groave in the pin correctly aligned with cotter pin hole, Fit the cotter pin (53), nut (54) and washer (56) but DO NOT tighten ut. Select shims (26) with a total thickness of approximately 020" (.6 mm) and place on top of bearing sleeve (27). Fit the bearing cone washer (24) and swivel pin nut (22), tighten nut Note: See Specifications, Section 2, for tightening torque values,MMEME SERVICE ——7 Vehicle Type: DR RANGE eerie ‘Subject: FRONT AXLE Repair Fig, 1 Exploded viow of stub axle and swivel ZESSERREBREBBBSRRE ‘Swivel Lubricator Nipple Swivel Top Cap Setserew Swivel Top Cap Spring Washer Swivel Top Cap Swivel Top Cap Joint Swivel Pin Nut Swivel Pin Sp. Pin Swivel Pin Washer ‘Swivel Becring Cone & Cup ‘Swivel Bearing Adjusting Shim ‘Swivel Bearing Sleeve ‘Swivel Beering Felt Wesher ‘Swivel Swivel Bottom Felt Retaining Ring Swivel Bottom Fett ‘Swivel Pin Bush (Bottom) Swivel Pin ‘Swivel Bottom Cap ‘0" Ring ‘Swivel Bottom Cap ‘Swivel Bottom Cap Serew Washer ‘Swivel Bottom Cap Setserew Brake Bracket Stud Hub Becring Distance Piece Brake Bracket LH. & R.H. Brake Bracket Nut 8 BaE8 57, 828 61 62. £8 Brake Bracket Spring Washer Brake Bracket Bolt ‘Chamber Bracket Stud LH Brake Actuator Brackot ‘Steering Lever/Brake Ch. Bracket Nut Lockwire Steering Lever Not Used ‘Swivel Stop Adjusting Washer ‘Swivel Stop Screw Washer ‘Swivel Stop Screw ‘Swivel Stop Nut ‘Swivel Pin Cotter ‘Swivel Pin Cotter Nut ‘Swivel Pin Gotter Washer Axle Bed ‘Steering Lever Stud (Bottom) Long ‘Steering Lever Stud (Bottom) Long Bottom Track Rod Lever (R.H. & LH.) Lubricstor ‘Steering Lever Nut Lockwire Track Rod Socket Assy R.H, (L.H, not shown) “This awe Poeaun UGH SERVICE fe 2 Vehicle Type: DR RANGE 7 subject!- FRONT AXLE. Repai Fig, 2 Swivel edjustment ‘Swivel adjustment: With a nominal shim thickness of .020" (0.6 mm) pleced between the bearing and bearing sleeve, attach a cord and a spring balance (see Fig. 2) to the end of the stub. Pull the nivel from lock to lock, noting the spring balance reading. ‘The correct reading should be 10 — 20 Ibs. if the reading is rot between these limits, it will bo necessary to alter the shim thickness between the bearing and its sleeve. To increase the force required, remove shims from the ‘nominal stack. To decrease the force required, add shims to the stack. ‘Add or subtract shims as required until a reading of 10 ~20 Ibs. is obtained, Provious true [Refer to Fig. 1) | is set correctly, check that the nut (22) is tightened. Fit split pin (23) and tighten cotter pin nut (54). Half fill the top cap (20) with grease and place in position ‘on swivel with @ new joint (21), securing with sotserews (18), and washers (19). Place a new ‘O° ring (34) in position on the bottom cap (35), apply grease around the ‘O' ring and fit the assembly into position in swivel, securing with setscrews (37) and washers (38). Locate the bottom track rod lever (59) on to its studs (57 58) and fit nuts (61). Tighten nuts and sacure with lock- wire (62). Position the cylinder bracket (45) on the studs (44), fit and tighten the nuts (46) and secure with lockwire, Re-connect the steering link and track rod to the steering lovers. Note: See Specifications, Section 2, for tightening toraue,Gr 18 TAG SERVICE = Vehicle Type: DR RANGE Section 2. ‘Sublet! FRONT AXLE Repair ‘To remove and dismantle ball socket assembly: (Refer to Fig. 3) Pull out the split pin (1) from ball pin (8) and remove nut (2) and washer (3), Using too!, part number X6661432, extract the ball pins (8), ‘complete with track rod assembly, out of the steering arm bosses, Examine the dirt seal pressing (5) and rubber (4) and renew if necessary. Remove the pinch bolt split pin (10) and nut (11) and loosen pinch bolt (13), unscrew the socket from the track rod, ‘Tho ball joint can be dismantled by first removing the split pin (12) and screwing out the adjuster piece (14). The spring (16) and thrust cap (15) can then be shaken from the socket, Use tocl X6652648 to screw out the edjuster, ‘To remove the ball pin (8) tap it on its threaded end, thus forcing out the ball pin and its thin cover plate (9): care ‘must be takn not to damage the thread when knocking out the ball pin, ‘The inner rubbing pad (17] can now be removed from the socket body (7) ‘Thoroughly clean all parts and check for wear, renewing where necessary, Koy to Fig. 3 1, Ball pin nut split pin 2. Ball pin nut 11, Socket pinch nut 3, Ball pin washer 12. Adjuster piece split pin 4. Dirt seal (rubber) 13. Socket pinch bolt 5. Dirt seal (pressing) 14. Adjuster piece 6. Grease nipple 15. Thrust cup 7. Socket body 16. Compression spring 8. Ball pin 17. Inner rubbing ped 9. Cover plete 18. Plastic plug Fig. 3. Ball Socket Assemblies 10, Socket pinch nut split pin 19. Tie rod owe Ua Thi leew‘subject! FRONT AXLE To assemble ball socket: (Refer to Fig. 3) Knock the rubbing pad (17) into its recess in the sovkex body (7). ‘Thoroughly grease the rubbing pad and tha ball pin (3) {it the ball pin into the socket body. Fit the cover plate (9) and secure by peeniny over in places with a cold chisel. Insert the thrust cap, compression spring anid axljusser pi tighten the adjuster piece fully home and then buck ex! Until one of the slots lines up with the split pins hole sw fit split pin (12). Use too! X6652548 for adjuster piove tightening. Fit the dirt seal pressing (6), securing by pesiing ov" four places with cold chisel Fit the dirt seal rubber (4) in position on the bal pls ‘Screw the ball socket assembly on to the track vox ay the socket assembly into position on steering arm anc washer (3) and nut (2}. Tighten nut end secure with 3 pin (1), Fit the pinch bolt (13) and nut (11) and tighten ws (1 and secure with split pin (10). Note: Before tightening the track must be set us fol Set the front wheels in the straight ahead position avi points level with the wheel contra, measure the distai«: between the edges of the wheel rims, both in front ar behind the axle centre. For correct ‘toe-in’ the front ‘measurement should be .0626" to .125" smatler then he rear measurement. To allow for inaccuracies in the wheels, the same check should be made with the vehicle moved an equivalent « Cone half of wheel revolution. Any adjustment required be affected by slackening the clarnp bolts in the ball Joi and rotating the track rod tube. After adjustment moke sure that the clamp bolts are tightened. Fit grease nipple (6) into the ball provided in the socks body (7} and charge the socket, with a lithiars bese! gr (See Specification Section). Note: See Specification Section fer tightening ti ne This teve [Presi tw SERVICE Repair iosele with the vehicle moved on equivalent to ‘nee! revolution, Any adjustment required can fackening the clamp bolts in the ball joints the tack rod tube, After edjustment make ‘tho clamp bolts ae tightened, «ing Pin and Steering Ball Joints to be greased ‘y sing Lithium based grease NLGI — No. 2.dm SERVICE . ‘Vehicle Type: DR RANGE a ‘Subject! FRONT AXLE Repair FRONT AXLE HUBfeet SGU SERVICE sim 8 ‘Vahl Type: DR RANGE Subject! FRONT AXLE Fig, 1 Stub axle and hub assombly RepairGrour 18 WIG! SERVICE : Vehicle Type: DR RANGE ee Subject). FRONT AXLE Repair Key to Fig.1 1. Hub Cop 2. Hub Cap Setserows 3, Hub Cap Wesher 4, Brake Drum Retaining Screw 5 Wheel Nut R.H. & LH. 6 Brake Drum 7. Hub Bearing Nut 8. Bearing Nut Pinch Bolt 9. Bearing Nut Pinch Bolt Nut 10. Hub Bearing Washer 11. Hub Cap Joint 12, Hub Bearing Cone (Outer) Cup 13. Hub 14. Wheel Stud RAH. & LH, 18. Hub Bearing Cone & Cup (Inner) 16. Hub Oil Seat 17, Swivel Lubricator Nipple 8, 1 Top Cap Setscrew 19, | Top Cap Spring Washer 20. Swivel Top Cap 21. Swivel Top Cap Joint 22. Swivel Pin Nut 23. Swivel Pin Sp. Pin 24, Swivel Pin Washer 25. Swivel Bearing Cone & Cup 26. Sivivel Bearing Adjusting Shim 27. Swivel Bearing Sleeve 28. Swivel Bearing Felt Washer 28. Swivel 30. Swivel Bottom Felt Retaining Ring 31. Swivel Bottom Felt Dismantling the Hub Assembly: To remove the hubs (Fig. 1 refers): sack up the vehi je and remove the road wheels, Back off the brake adjustment, Remove the brake drum retaining setscrews (4). Support the brake drum (6) with a rope sling and pull the ‘drum from the wheel studs. Remove the hub cap setscrews (2) and washers (3), the hub cap (1) and joint (11) can then be removed. Slacken the hub nut pinch bolt (8) and remove the hub nut (7) and pull off the washer (10). ‘The hub (13) complete with its bearings and oil seal can then be removed. RBRABSRIR ASE Swivel Pin Bush (Bottom) ‘Swivel Pin Swivel Bottom Cap ‘O" Swivel Bottom Cap Swivel Bottom Cap Screw Washer Swivel Bottom Cap Setsorew Brake Bracket Stud Hub Bearing Distance Piece Brake Bracket L.H. & R.H. Brake Bracket Nut Brake Bracket Spring Washer Brake Bracket Bolt ‘Chamber Bracket Stud LH. Brake Actuator Bracket Steering Lever/Brake Ch, Bracket Nut Lockwire Not used Swivel Stop Adjusting Washer Swivel Stop Screw Washer Swivel Stop Screw Swivel Stop Nut ‘Swivel Pin Cotter ‘Swivel Pin Cotter Nut ‘Swivel Pin Cotter Washer Axle Bed ‘Steering Lever Stud (Bottom) Long Steering Lever Stud (Bottom) Long Bottom Track Rod Lever (R.H. & L.H.) Lubricator Steering Lever Nut Lockwire Track Rod Socket Assy. R.H. (LH. not shown) ing Remove the oil seal (16) from the hub and, using a suitable rift, Wtthe drive out the beatings (12) and (16) from the hub. oil seal wear sleeve (39) shows signs of wear or corrosion it must be removed and replaced with e new pert, Inspection: Thoroughly clean all the parts. Inspect all parts for wear and renew if necessary. Parts such as ol seals and paper or cork je joints should be renewed whenever they have been removed. Note: Before the Stub Axles can be overhauled the brake assemblies must be remaved. This can be dane without the need to completely dismantle the brake Previo “Thi eeMG SERVICE Vehicle Type: DR RANGE Subject), FRONT AXLE Disconnect the brake cylinder push rod from the brake lever slack adjuster. Remove the nuts (41), washers (42) and setscrews (43) securing the brake bracket (4) to the swivel (29), The complete Brake Assembly can then be removed from the axle, Assembly of Front Hub: Brake Assembly (Fig. 2 refers): Fit the complete brake assembly on to the swivel stub, locating on the brake backplate studs (38). Seoure with ruts (41), spring washers (42) and sotscrews (43), Refer to the Specification Section for torque value, To assemble hubs (Fig. 2 refers): = Fit the oil seal wear sleeve (39) on to the axle stub (29). Fit the inner and outer bearing cups into their bores in the fhub (13). Pack the hub and bearings with grease. Fit the inner bearing cone in to its cup in the hub (13) Press the hub oil seal (16) into position in hub. Fit the hub assembly on to the axle stub and assemble the ‘outer bearing cone into its cup. Replace the bearing washer (10) and bearing nut (7) and tighten hard with the aid of a tommy bar, at the same time revolving the hub. Adjust end float (see below for method). Pack the hub cap (1) with gfease, Fit the hub cap (1), with new joint (11) and secure with setscrews (2) and spring washers (3). Refit the brake drum (6) securing with setseraws (4), Re-adjust the brakes and refit the road wheels and wheel studs (5). Tighten studs. Notes: See Specification Section for tightening torque values and recommended lubricant, Previous tssue Adjustment of end float Fig, 3 refers unless stated otherwise) ‘The hub should rotate quite freely without eny roughness. Slacken the bearing nut (7) back approximately 20°, Mount 2 dial indicator on the hub flange and rock the hub back- wards and forwards along the stub, taking a reading on dial indicator. (See Fig. 4). ‘Tho correct end float should be between the limits .004"/ 006". (0.1/0.15 mm). If the reading obtained is not within these limits, adjust the beering nut until the correct reading is obtained. Fit the bearing nut pinch bolt (8) and nut (9) and tighten to lock the hub nut (7). Note: See Specification Section for tightening torque values.TG SERVICE eae Vehicle Type: DR RANGE Subject! FRONT AXLE Repair Fig. 3 Adjusting end floatSGM SERVICE Vehicle Type: DR RANGE Subject: FRONT AXLE crow 18 Section 1 Specifications BRAKES TIGHTENING TORQUES for 15%" x 8” Cam Brake: Refer to Sections 2 & 3, Specifications LUBRICANTS Lithium based roller bearing grease NLGI No. 2, Grade F, to be used on: Brake cam bushes (21) — grease monthly Pivot pin bushes (4) — grease 3-monthly Gear oil to be used on: Brake linkage — oil monthly Fig. 1 Broke assembly a Previous tueMmcur SERVICE Vehicle Type: DR RANGE Subject! FRONT AXLE STUB AXLE TIGHTENING TORQUES 18 Swivel Top Cap Setscrew 2 ‘Swivel Pin Nut 37 ‘Swivel Bottom Cap Setscrew Brake Bracket Stud “1 Brake Brecket Nut a4 (Chamber Bracket/Top Lever Stud 48 ‘Chamber Bkt. Nut 54 Swivel Pin Cotter Nut 57&58 Bottom Steering Lever Stud a ‘Steering Lever Nut ig 1 Stub Axle Assembly 43/47 Ibs ft. (6.9/6.6 Kam) 300/600 tbs ft (41.5/69.1 Kam) 28/31 ths.ft (3.9/4.4 Kam) 40/44 Ibs. ft. (6.5/6.1 Kam) 66/74 Ibsft (9.2/10 Korn} 180/220 tbs. fe. (25/30 Kom) 180/220 ths. (25/30 Kam) 153/59 Ibs. ft. (7.478 Korn) 180/220 Ibs. ft (25/30 Kam) 180/220 Ibs. ft. (26/30 Kam) Specifications LUBRICATION Bearings: ack with grease on assembly. Clean out and recharge annually. Use Lithium based roller bearing greese NLGI — No. 2.MG | ohiete Type: DR RANGE [__sineee_ FRONT AXLE SERVICE Grow 18 section 3 Specifications FRONT AXLE HUB TIGHTENING TORQUES tem Description No. 2 Hub Cap Setserew 5 Wheel Nut 8 Bearing Nut Pinch Bolt Nut LUBRICATION Bearings: Pack with grease on assembly. lean out and recharge annually Use Lithium based roller bearing grease NLGI — No. 2. Fig. 1 Front axle hub assembly Torque 16/18 Ibs. ft. (2.2124 Kam) 380/420 Ibs. ft (63/58 Korn) 24/26 Is. ft. (3.3/3.6 Karn)Group REAR AXLE WG SERVICETEM SERVICE ane, Section 0. Vehicle Type: DR RANGE Subject! REAR AXLE Contents list Main | Section | Page Numbers ana Subs - To | A [5° General 1 Rear Brakes 1 Brake assemblies - Servicing To remove the brake drums Dismantting Inspection Assembly Fitting and adjusting slack adjusters Technical Description 1 D 65 Rear Axle Hub 1 Rear axle hub - Servicing Annulus and hub removal Hub and brake drum removal Inspection Hub and brake drum assembly Installation of oll seal Installation of new wear sleeve Bearing adjustment assembly of planet gears 1 D 65 Axle Driving Head 1 ‘Axle driving head - Servicing Dismantling Gear cesing from axle casing Differential ‘Assembly Differential Pinion/pinion bearing housing Setting the erown wheel and. Checking the crownwheel and pinion mesh Filling Repair ‘Specifications i i 2 q 4ov * TMEW SERVICE Sstamslites Vehicle Type DR RANGE Subject: REAR AXLE Technical Description Slack acjustrs 7— fh 1080 mm Trock | 2956 mm Overs | AXLE RATIOS Fig. 1a Rear Axle, Plan View Noot Teeth spiral Oval il filler drain plug Bat val Pinion wheet Ratio ato. aban 2 371789 108 2 ae s.871 271.8417 6.167 Oit evel plug (Oi drsin plug clase U" bolt Fig, 1b Rear Axle, Elevation aoe “This ese ieGUI SERVICE Group 20 Vehicle Type! DR RANGE Section 0 ‘Subic! REAR AXLE GENERAL ‘The rear axle is @ modified D.65 Kirkstall semi-drop hhub reduction axle with built in anchorages for control links. ‘The hollow axle casing assembly has the differential housing positioned to the right of the axle, when viewed from the rear of the vehicle. The differential input shaft is angled 10° away from the contre of the vehicle. ‘The differential output driving shafts drive the hubs, ‘which carry the brake drums and wheels, through pinion and planet wheel gearing. ‘Three variations in axle ratio are possible, The standard ratio of .1:1 and two alternatives of 6.7:1 and 6.1:1 The brakes are Kirkstall supplied and are provided with SAB automatic wear adjustment. The brake drums, constructed of special alloy cast iron, are carried on the ‘outside of the hub flanges. Design of the brakes permits brake servicing without disturbing the hub. Previous lee Technical DescripticMEM! SERVICE Vehicle Type: DR RANGE Section 1 Subject!’ REAR AXLE ‘Technical Descriptio REAR BRAKES 108 assemblis are hinged on pivot pins /@ maintained clear of the brake drum, in the ing position, by the brake shoe return springs, application is made by expanding the brake shoes against the drum. This is achieved by turning to exert pressure on the shoes through shoe rollers. The turning moment is applied ke actuating mechanism to the ’S" cam shaft SAB slack adjuster. Brake shoe return spring Fig, 1 Brake assamblyMc SERVICE erat Vehicle Type: DR RANGE ‘Subject! REAR AXLE 65 REAR AXLE HUB “The hub gears are driven by ‘floating’ sun pinions splined to the driving shafts. Each pinion rates with ‘three planet pinions mounted on a rabust carrier Which is bolted to the whee! hub. The annulus is of the two piece variety and splined on to the axle arm. It also serves to support the outer hub bearing, Section 2. Technical Descriptic Brake drum \ / ‘Annus g. 2 Fig. 1 Rear Axle Hub AssemblyMEW SERVICE Grou 20 \Vohicle Type: DR RANGE Subject! REAR AXLE D 65 AXLE DRIVING HEAD GENERAL ‘This differential has an overhung spiral bevel pinion inted. in widely spaced taper roller bearings, each ing adjustable by packing shims. The crownwheal is of a heavy section, also mounted in taper roller bearings ‘Three pinion and crownwheel combinations are available, giving a standard ratio of 5.1 : 1 and two alternatives of 6.87 : Vand 6.1: 1 ‘The differential has four differentia! pinions and the ifferential cage runs in taper roller bearings positioned on either side. Pinion bearing housing Crown neo! ‘ond pinion Coupling flange ‘Axle casing evel pinion ‘and bush Spider Ditterental siustng nut Previous Ine | Section 3. Technical Descriptio,WCU SERVICE aeTet ‘Vehicle Type: DR RANGE ae Subject: REAR AXLE Repair BRAKE ASSEMBLIES — SERVICING Note: a) Holes are provided in the hub to allow the brake shoe pivot pins, and the shoes themselves, ‘to be romoved with hub in place. For this operation the brake drums must be taken off. 'b) When camshafts have been removed they should bbe marked. to ensure that they are replaced on the same side of the axle from which they were removed To remove the brake drums: Jock up the vehicle and remove the road wheels. Back off the brake adjustmont, Remove the brake drum retaining setserews, Support the brake drum with a rope sling and pull the drum from the wheel studs. Return spring x 6651464 Fig. 1 Relieving spring tension “Thi eeu Pacei STNG SERVICE ere Voile Type: DR RANGE subject! REAR AXLE Repair Fig. 2 Brake assomblyNGM SERVICE ere Secon 1 ‘Vehicle Type DR RANGE ‘Subject! REAR AXLE Repair Key to Fig. 2 Dismantling: Brake bracket (Fig, 2 rotors unless stated otherwise) Brake shoe assembly Brake shoe bush Using too! X 6851464 as shown in fig. 1, relieve the tension Brake shoe roller spring (11) and pull out the anchor pins (14). A wire hook Brake shoe rollar pin ‘an be inserted through the holes in the pins for easy removal, Split pin A Pivot pin Remove the return springs. Pivot pin setscrew Pivot pin washer Remove the setserews (8) and focknuts (2) securing the Pivot pin setserew ‘brake shoe pivot pins (7), drive out the pivot pins and Brake shoe return spring remove the brake shoes (2). Brake bracket anchor pin ‘Anchor pin spring washer Disconnect the slack adjuster lever (38) from the brake Brake shoe anchor pin actuator, Split pin Not used Remove the crcip (41), wesher (40) and spring (29) which Not used ‘the slack adjuster! pull the adjuster from the ca Greasing extension sheft (28). Groate pl Grease plug wesher Withdraw cama from brackets (34) and (1) along with Not used its head washer (26) and ‘O" ring (27). Not used Not used Remove nuts (17) and bolts (16) securing the brake Not used bracket (1) and take off the brake bracket. Likewise, Brake camshaft remove the nuts (36) and washers (35) and take off the Brake cam washer camshaft bracket (34). Cam ‘Oring Cam bush Remove the bushes (28) and oil eal (29) from brake Cam oil collector brake bracket, also bushes (38) and oll seal (32) from Cam bracket setscrew (short) cam bracket. Cam bracket setscrev (long) Cam bracket oft collector ‘Note: When removing O/S slack adjuster itis necessary Cam bracket bush first to withdraw the brake camshaft partially. Com bracket Cam bracket spring washer fasgaation: Gam bracket nut Grease nipple ‘Aftor carofully cleaning the various parts they should be Slack edjuster inspected for wear and renewed if necessary. Cam spring Washer A light smear of grease should be given to the bearings Chrelip and pivot pins before they are reassembled, using Brake drum Lithium based roller bearing grease NLGI - No. 2. Previous ts This tse raeGroun 20 cul SERVICE Vehicle Type: Subject: REAR AXLE Assembly: (Fig, 2 refers unless stated otherwise.) Tools required: X 6651464 - For fitting brake shoe return spring X 6851465 - For fi ‘cam bracket bush X 6851466 - For fitting brake shoe bush X 6651467 - Handle for bumpers X 6651485 and X 6951466 Fit brake bracket (1) and secure with nuts (17) and. bolts (16). Fit new bush (33) and oil seal (32) in camshaft bracket (34) and ensure that the oil holes are in line, Fit the camshatt bracket (34) on to axle casing with stud (30), spacer washers (31) and washers and nuts (35 & 26), Slide the head washer (26) end '0" ring (27) on to the camshaft (25); ensure that the cams are replaced ‘on the seme side of the axle from which they were removed, Fit the bushes (3) into position in their housing in the brake shoes (2); peen the bush and shoe as shown in Fig. 3 equi-spaced in three places to key the bush in position. Locate the roller (4) in position, fit the roller pin (5) s0 that the headed portion will be towards the brake bracket when fitted and secure in place with split pin (6). Splay the split pin (6) to approx. 30° as shown in Fig, 4 to. fracture of leg. Mn brake shoes (2) on brake bracket (1) and drive ‘home the pivot pins (7), secure in position with their lock screws (8) and lock nuts (9) ‘Seat the brake shoe rollers (4) in position on camshafts (25) 0 that the rollers lie in the two depressions, (ee Fig, 5). This ensures that the cam is in the correct ‘operating position. Fit the brake shoe return spring (11). The spring can be extended with the aid of a special toot X 6651464 (Fig, 6) white the retaining anchor pin (14) is repositioned Fit the slack adjuster (38) to the camshaft as detailed below. DR RANGE Repair Replace washer (39), retaining spring (40), washer (41) and circlip (42). Fit the brake drum and secure with four setscraws, Notes: 1) For tightening torque values, refer to Specifications 2) When re-assembling the O/S brakes it is necessary tq withdraw the brake camshaft partially to refit the slack adjuster. Fitting and adjusting SAB slack adjuster: Fit SAB slack edjuster (Fig, 2, item 38) yo the camshaft (Fig, 2, tem 28) ensuring that the arrov}, on the adjuster arm, points in the direction of brake application. Ensure that brake actuating piston push rod is fully retracted into brake eylinder. Using a 12mm spanner on the slack adjuster adjusting hexagon, align the hole in the adjuster control arm with the hole in the piston rod elevis, Fit clevis pin without moving piston rod or slack adjuster control arm. Push adjuster control arm as far as it will go in the direction of brake application. When in this position secure to the anchor bracket with the bolt. Refit brake drums and secure with four setscrews, Manually adjust the brakes, with 12 mm spanner, to ‘approximately the correct running clearance,TIEMEL SERVICE ane ‘Vehicle Type: DR RANGE ete ‘Subject! REAR AXLE Repair Fig. 4 Securing roller pin Fig, 6 Fitting brake shoe return springMGW SERVICE ieee Vehicle Type: DR RANGE ‘Subject! REAR AXLE Repair D 65 REAR AXLE HUBGrove 20 mc SERVICE Section 2. Vehicle Type: DR RANGE Subject’ REAR AXLE Fig, 1 Reear axle hub assemblyMew SERVICE tae Vehicle Type DR RANGE Subjet: REAR AXLE Planet pin expansion plug Planet carrier setserew Setscrew washer Planet carri Planet carrier ‘O' ring Thrust washer Planet whee! Neadle rallor 10. Spacer 11. Thrust wather 12, Planet pin 13. Roll pin 14, Dowel 15. Circlip 16. Sun gear 17, Thrust washer 18. Axle tube nut 19. Washer 20. Axle tube nut 21. Dowel 22. Annulus gear 23. Lock plate 24. Setscrew 25. Annulus carrier 26. Outer hub bearing 27. Dowel 28. hub 29. Wheel nut 30. brake drum setscrew 31. Not used 32. Brake drum 33. Wheel stud 34. Lockplate 35. Locknut 36. Driving shaft 37. Inner hub bearing 38. Spacer 39. Hub oil seal 40. Hub ail collector 41. Axle housing REAR AXLE HUB — SERVICING Dismantling: (Refer to Fig. 1.) Remove the drain plugs from the hubs and the differential housing and drain the oil from the axle hubs and differential Siacken off brake adjustment. Remove the planet carrier set screws (3) Using two 3/8" U.N.F. bolts screwed into the holes provided, withdraw the planet carrier (5) and planet gear assembly. Using a rnetal rod, smatier in diameter than the roll pin (13), tap out the pin, Screw a 3/8” U.N.F. bolt into the tapped holes pro- vided and pull out the planet pin (12). Carefully lift the planet gear (8) through the opening in the planet carrier (5). Take care not to lose any of the forty four needle roller bearings (9) from the planet gear bore. ‘Also remove the thrust washers (7 & 11) from the planet carrier. ‘The remaining two planet gear assemblies can now be removed In the same manner as described above. ‘Annulus and Hub removal: Life the eirctip (15) from its groove in the drive shaft (36). The sun gear (16) together with its thrust washer (17) can now be pulled from the splined shaft, Reliove che tab washer (18) from the inner {18} and ‘outer (20) axle tube nuts. Unserew and remove both axle tube nuts (18 & 20), Tho annulus carrier (26) is removed from the axle arm by serewing '4"" U.N.F. bolts in to the tepped holes provided and tightening. As the annulus is withdrawn in the manner described ‘ebove, the cone of the outer hub bearing (26) is pushed from the annulus carrier. This can be removed rom the hub after the annulus has bean removed. This leave Pave a atigust roaa aow GUE SERVICE pean 2 Vehicle Type DR RANGE Subject, REAR AXLE. Repair Hub and Brake Drum removal: Support the hub and brake drum assembly with & rope sling and pull them from the axle, The outer bearing cup (26), inner bearing (37) and oil seals (39 & 40) will come away with the hub. Separate the brake drum from the hub by unscrewing the setscrews (30). Remove the hub bearing cups and oil seals from the hub. Using tool X 6651426 remove the oil seal wear sleeve (38) from the axle arm. {f for any reason the wheel studs (33) need removing bend down the lock plates (34) and unscrew the nuts (25), tap out the wheel siud, Inspection: After carefully cleaning all the verious parts, they should be inspected for wear or damage, Any parts found to be defective in any way should be renewed, ‘The oil seal wear sleeve, oil seals, joints (either paper or cork} and thrust washers should be renewed as a matter of course at each overhaul Hub Oil seal spacers wer Bearing cup ~ Bearing cone Fig. 2 Installation of oil seal me “Thi eve Previous 4 | 4 aucust 1980 | | Apply Loctite RTV 1 ‘completely around outside face, Hub oil sealMet SERVICE oti Vehicle Type: DR RANGE Section 2 Subject: REAR AXLE Assembly: Hub and Drum assembly: ( ig. 1 refers unless otherwise indicated.) Press the inner (37) and outer (26) bearing cups into the hub. Place the inner bearing cone (37) into its cup. Assemble the oil seal(s) (39 & 40) into position on the hub 1 described bolow, (Soe Fig. 2) ‘A new oil seal wear sleeve (38) must be fitted as described below. (See Fig. 3. I any wheel studs (33) have been removed, refit their replacements into the hub (28), fit the locking plate (34) and nut (35) and tighten, The hub (28) can now be fitted in position on the axle arm. Carefully guide the inner bearing (37) along axle arm, also take care not to damage the delicate seats (39 & 40). Support the hub and broke assembly until the annulus has been fitted. Press the cone of the outer bearing (26) on to the annulus carrier (25). If the annulus (22) and carrier (25) have been separated, assemble the annulus on to the carrier. Fit the lockpletes (23) and setscrews (24). Tighten screws and lock in position by bending over the lockplate tabs. ‘Assemble the annulus assembly on vo the splines of the axle arm, Wear sleeve Flush with shoulder Fig. 3 Positioning of wea Previous fsue Repair Fit the inner axle tube nut (20) and tighten hard, so as ‘to ensure that the bearings are pushed home. Siacken back the inner tube nut Follow instructions for “Bearing Adjustment”, Note: For tightening torque values see “Specifications”. Installation of oil seal (Refer to Fig. 2) Special tool: Oil seal bumper Pt, No. X 6652568 Fit the oil seal spacers into the hub bore against the hub baaring cup. Knock the oil sea into position with oll seal bumper. ted , apply a film of Loctite RTV 1 (Superflex) between the outside diameter of seal and ‘the hub bore, This prevants leakage around seal outside diameter. Installation of new wear stoova: Clean the stub arm free from grease using trichlorethy- lene. Apply a bead of Loctite plastic sealing compound No. 601 ‘completely around the stub as shown in Fig. 3, particularly on underside, ‘Assemble wear sleeve on to axle arm and allow 2 hours. to cure, Axle stub " Loctite 601 fe senctng sleeve This tsvewou 20 etion 2 ag SERVICE Vehicle Type: DR RANGE ubject!- REAR AXLE Repair Bearing adjustment: (Refer to Fig, 1 unless otherwise stated.) ‘Mount a magnetic dial indicator on to the hub. Position the pointer of the indicator against the axle arm, of any part which will remain stationary when the hub is rocked backwards and forwards. Rock the hub assembly backwards and forwards (see Fig. 4) and note the variation shown by the indicator. ‘The permissible variation is 0.003"/0,008" end float in the bearing. To obtain the correct setting adjust the inner hub bearing rut (20) until the correct variation is ac Fig. 4 End flost adjustment Fit the bearing nut lockplate (19) and outer bearing nut (18) and tighten. Care must be taken not to disturb the inner bearing nut. Lock the nuts in position by peening over the bearing lockplate. ‘At the first vahicle sorvice, and subsequently et three monthly intervals, check that no excessive float has occurred in the hub bearings and thst the deflection is within the sbove limits, Inspect the hub and planet carrier for any signs of oil leakage and rectify as necessary.MGM SERVICE DR RANGE ‘Vonicto Ty Subject: REAR AXLE Re. sembly of planet gears: ‘Assemble the sun gear thrust washer (17) over the drive shaft and locate on the axle arm, Fit the sun gear (16) on to the splined drive shaft. Tap, into position and fit circlip (1) into its groove. Each planet gear must have a set of forty four needle roller bearings and a bearing spacer in its bore, Proceed as follows: ‘Smear the bore of each planet gear (8) with grease. ‘Assemble twonty two needle roller bearings (9) into fone end of the gear. Turn the gear round and fit the bearing spacer (10) Into the bore. Now asserable the remaining ‘twenty two needle roller bearings into the plenet gear bore. Position two planet gear washers (7 & 11) into. the planet carrier opening; ensure the tongues it snugly into their slots. Carefully place the planet gear assembly through the planet carrier opening. Slide the planet pin (12) into pposition through the carrier and gear. Using the 3/8” U.N.F, extractor bolt, rotate the planet pin (12) until the roll pin (13) can be knocked into position. Unscrew the extractor bolt, ‘After assembling each planet gear, make sure that the sun {ear thrust button (14) isin position in the planet carrier, Fit a new planet carrier " in the planet carta ing seal (6) into its groove ‘Assemble the planet carrier and gears into position on the hub. Replace setscrews and hardened washers (4) and tighten. If the brake drum (32) has not yet been replaced, fit it on to the wheel studs; ensure that the securing holes align with, ‘those in the hub. Fit the breke drum retaining screws (30) ‘and tighten. Refill the hub with the correct grade end quantity of lubricating oil. (See Specifications) Rofit fillerlovel plugs (1). Note: For tightening torques sce “Specifications”. Grows Seetion Repair 20URGU SERVICE ae Vehicle Type: DR RANGE puuniiid Subject! REAR AXLE Repair D 65 AXLE DRIVING HEADTAG SERVICE Vehicle Typet DR RANGE Subject! REAR AXLE Repair AXLE DRIVING HEAD — SERVICING Dismantting: Note: Before starting to dismantle a differential the oll must be drained frorn the axle cantra; this Is best done after @ short run to warm the oil, and the driving shaft removed. Fig 1 Driving Head Assembly ‘This asus Previous lsu aauierisT 19Rnrou 20 INGUE SERVICE = Voila Type: DR RANGE eee Subject! REAR AXLE Repair Key to Fig. 7 1. Coupling flange nut 2. Coupling flange washer 3. Coupling flange 4. Pinion oil seal 5. Outer pinion bearing 6. Pinion bearing spacer 7. Inner bearing spacer 8. Pinion bearing housing 9. inner bearing shim 10. Pinion bearing housing setscrow 11. Inner pinion bearing 12. Bevel casing assembly 13, Casing strap stud 14, Casing strap nut 18. Casing strap washer 16, Axle casing joint 17, Axle casing stud 18, Axle casing nut 19. Axle casing spring washer 20. Crownwheel and pinion 21. Differential adjusting nut 22, Adjusting nut split pin 23, Differential bearing 24. Differential cage 25, Differential cage bolt 26, Differential cage nut 27. Differential cage washor 28, Donel 29, Thrust washer 30. Bevel whee! 31. Bevel wheel and pinion 32, Thrust washer 33. Spider 34, Drain plug 35, Filler/level oll plug 38, Axle casing Dismantling: Gear casing from the axle casing’ (Fig. 1 refers.) Ensure the gear casing (12) is well supported from above and ramave the axle easing nut (18) and spring washer (19). Insert 2- 6/8" U.N.F. bolts in the two extractor holes provided in the rear casing flange and screw far enough to separate the goar casing (12) from the axle casing (36). Remove the coupling flange steke nut (1) and washer (2) and pull the coupling flange (3) off. (See Kit X 6852569 for extraction equipment if required. Unscrew the bearing housing bolts (10). Lift off the bearing housing (8) along with the inner and outer pinion bearings (11 and 6), pinion oil seal (4), bearing spacers (6 and 7) and shims (9). The oll seal (4) can now be removed and checked. for damage, Remove the outer bearing cone (5) and préss. ‘the pinion out of the housing, leaving the inner and ‘outer bearing cups (11 and 5) in the bore of the housing. “The spacers (6 and 7) and shims (9) can now be removed. Differential: Remove the differential bearing strap nuts (14) and spring ‘washers (15) and remove strap. Remove the differential bearing adjusting nuts (21) and split pins (22) Remove crown wheel nuts (26) and washers (27). Drive out crown wheel bolts (26) taking care not to damage threads, Remove the crown wheel (20) “The two differential cage halves (24) can now be separated after first marking the two halves to ensure correct re-assombly. ‘The bevel wheels (30) and thrust washers (28) can now be removed along with the spider (33) the differential bevel pinion and bush (31) and thrust washer (32) Draw the bearings (23) from the differential cage halves, Assembly: To assemble the differential: (Fig. 1 refers) ‘Take the flanged half of the differential cage (24) and replace the crownwheel (20) locating with the dowel (28). Press the differential bearings (23) on each half of the differential cage Previous ae