Service and Repair Manual

Type : FL 22/0 Planetary Rigid Axle for Microscoop 100

Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

TABLE OF CONTENTS
1 GENERAL AND SERVICE WORK 2
1.1 Introduction 2
1.2 Ordering of Spare Parts 2
1.3 Working Conditions and Tools 3
1.4 Service Work 3
1.4.1 Lubrication Table 3
1.4.2 Service Interval 4

2 REPAIR MANUAL 7
2.1 Exchange of the Complete Differential 7
2.2 Repairs on the Differential 8
2.2.1 Exchange of Crown Gear / Pinion 8
2.2.2 Exchange of Differential Cage (No - Spin Compensator) 16
2.3 NoSpin 17
2.3.1 How to test the NoSpin 17
2.3.2 How the NoSPIN operates 18
2.3 Planetary Drive 20
2.3.1 Exchange of Complete Planetary Cage 20
2.3.2 Exchange of Sun Gear Shaft 21
2.3.3 Exchange of Planetary Gears 22
2.3.4 Exchange of Planetary Pins 23
2.3.5 Exchange of Crown Gear Carrier 23
2.4 Wheel Bearing 24
2.4.1 Wheel Bearing Exchange 24
2.4.2 Wheel Bearing Adjustment 25
2.4.3 Exchange of Axial Face Seal 25
2.4.4 Check Thrust Stud Adjustment 26
2.4.5 Exchange of the Axle Stub 26

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

1 General and Service Work

1.1 Introduction
The series production of FL 22 began in June 1996. This model contains a permanent differential lock
(No-Spin), which will allow for compensation, when a predetermined power point is exceeded. The
two outer planetary drives are driven by sun gear shafts. The axle is rigid and is constructed for direct
frame mounting. The main drive is achieved over a cardan flange ∅ 100.

1.2 Ordering of Spare Parts

Spare parts for these NAF Axles should best be bought direct from an official TAMROCK supplier,
whereby many of the important parts are conveniently stored and available for delivery. Even when
parts are not immediately available, it is recommended to order from the supplier and not from the
factory. The supplier can usually describe the necessary part more accurately and give the part number
more precisely and therefore avoid errors and mistaken shipments.
For every spare part delivery, it is important to give the full and exact type name with factory number
and year of fabrication. The type sign is located on the Diff.-Housing near the oil fill plug (refer to Fig.
1).
Use only original NAF spare parts. Use of parts from other manufacturers voids every warranty and
may lead to impaired function such as service life.

Fig. 1

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

1.3 Working Conditions and Tools

A clean and well-lit work environment is necessary for an orderly repair. There should also be enough
room available to lay out the various parts and sub-assemblies and to put them in order.
Furthermore, a complete as possible quality tool set of all important tools and basic hardware is
needed. Additionally, certain special tools are also necessary, which usually prove to be of invaluable
help, especially, when one must perform certain repairs frequently. One spares oneself a lot of time
and frustration. The specialty tools will be described in the subsequent sections, i.e. marked (e.g. with
Sk.Nr.).
Furthermore, a certain expertise, and for some repairs, even specific training is necessary.
1.4 Service Work
1.4.1 Lubrication Table
Lubrication Table for FL 22/0

Lubrication Nr. Fill Quantity Lubricant

Location
Differential 40/42 4.0 Litre SAE 90 (Hypoidoil)
Planetary Drive 50/51 1.5 Litre SAE 90 (Hypoidoil)
Description of the Lubricating Location Numbers:
Nr.: 40 ⇒ Oil-Fill-and Oil-Level checkplug for Differential
Nr.: 42 ⇒ Oil-Drain plug for Differential with magnet
Nr.: 50 ⇒ Oil-Drain plug for Planetary Drive with magnet
Nr.: 51 ⇒ Oil-Fill plug for Planetary Drive
(refer also to Fig. 1 and 2)
Examples for Brand-EP-Transmission Oil SAE 90 specification: API-GL 5 or MIL-L-2105 B
DEA (Multigear EP 90) / (Geartex EP-B SAE 85W 90)
Mobil (Mobilube HD 90-A) / (Mobilube SHC 75 W-90)
Esso (GX 90)
Shell (Spirax HD 90) (Spirax MB 90)
BP (Hypogear 90 EP)
ELF (Tranself Typ B SAE 80W-90)
Texaco (Geartex EP SAE 80W)
Please refer to the legend of the Lubrication Plan concerning the fill quantity.

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

1.4.2 Service Interval

NAF-Axles are designed and built from long-term experience and knowledge of work machines.
Proper functioning and constant work readiness is only achieved if the axle is well cared for, properly
handled and regularly serviced. This includes compliance with the service interval, the use of
appropriate lubricants corresponding to the Lubrication Table and checking various service points.
Special tools for maintenance work are not necessary.

Service Interval Table for FL 22/0

Operating Hours 0/ Initiation After 1 -250 250 500 2000
day (every) (every) (every)
or 1x
Service Location (Nr.) annually
Differential (40/42) 1 2 3 2
Planetary Drive (50/51) 1 2 3 2
Wheel nuts 4 4 4 4
All visible nuts and bolts 4 4

1 = First Filling (see section 1.4.2.1)

2 = Oil change (see section 1.4.2.2)
3 = Checking Oil level (see section 1.4.2.3)
4 = Inspection (see section 1.4.2.4)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

1.4.2.1 First Filling

Caution! The planetary drive is delivered from NAF without oil.
Explanation: The oil chamber of the planetary drive is sealed to the outside with an axial face seal. Wheel
hubs and planetary drives have a common oil chamber. Due to the narrow through hole to the sun gear
shaft, and therefore relatively slow oil passage, both oil chambers must be filled or added with oil into
each of the provided openings.
• Differential
Remove oil fill plugs (Nr.40) and fill oil corresponding to the Lubrication Table, until the oil
reaches the lower lip of the thread. Check after approx. 5 minutes oil level, and if need be, add oil.
Tightening moment for the oil fill plug (Nr.40) is 53 + 10 Nm. (see Fig. 1)
• Planetary-Drive
Turn both wheel hubs until the screw plugs (Nr.50) are horizontally. Remove screw plugs (Nr.50)
and fill oil corresponding to the Lubrication Table into the upper opening, until the oil level reaches
the lower lip of the horizontally thread.
Tightening moment for the screw plugs (Nr.50) is 53 + 10 Nm. (see Fig. 2)
1.4.2.2 Oil Change
Note: Clean the area around the screw plugs (Nr. 40/42/50/51) from all dirt
• Differential
Perform oil change when oil is warm. Remove oil fill plug (Nr.40) then open oil drain plug (Nr.42).
Drain oil completely. After draining oil from the planetary drive fill new oil corresponding to the
Lubrication Table. Tightening moment for oil fill- and drain plug is 53+ 10 Nm. (Fig. 1)
• Planetary-Drive
Perform oil change when oil is warm, simultaneously with the differential. Turn the wheel hubs
until the oil drain plug (Nr.50) is vertically down in the axle centre. Remove oil drain plugs (Nr.50)
and drain oil completely. Then insert oil drain plugs (Nr.50) again (see Fig.2). Remove oil fill plugs
(Nr.51) and fill new oil corresponding to the Lubrication Table to lower lip of thread (Nr.50).
Tightening moment for screw plugs (Nr.50/51) is 53+10 Nm. (see Fig. 2)

Fig. 2

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

1.4.2.3 Checking Oil Level

Note: Clean the area around the screw plugs of dirt beforehand
• Differential
Remove oil fill plugs (Nr.40), if required add new oil corresponding to the Lubrication Table.
Tightening moment for oil fill plug (Nr.40) is 53+10 Nm.
• Planetary-Drive
For this, turn wheel hubs until screw plug (Nr.51) is horizontally, remove screw plug (Nr.51), the
oil level should be at the lower bottom edge of the thread. If required add new oil corresponding to
the Lubrication Table. Tightening moment for the screw plug (Nr.51) is 53+ 10 Nm (see Fig. 2).
1.4.2.4 Inspection
• All visible bolts and nuts
Due to stresses and vehicle vibrations, it is possible for various bolts and nuts to „set“ or give way.
Timely tightening of these will prevent any leaks or other greater damages.
Note: The adhered nut for the cardan flange attachment (pinion nut) must not be tightened.
• Wheel-Nuts
Due to stresses of vehicle motion, the wheel nuts may “set” or loosen. Timely tightening will
prevent a deflection of the centre of the rim. Tightening moment for wheel nuts is 440 Nm.

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2 REPAIR MANUAL
2.1 Exchange of the Complete Differential
(see Fig. 3 )
Note! For large damages to the differential it may be more advantageous to exchange the complete
differential instead of repairing it.
• For this it is advantageous to remove the complete axle from the undercarriage.
• Drain the oil from the differential
 • Screw off hex.-nut (Nr.2) on both sides of the differential, and take off and pull out axle beam
(Nr.1) with sun gear shaft (see Fig. 3)
• Exchange of Differential
Note! Original NAF spare and repaired differentials are properly set-up and adjusted from the factory.
Differentials not from NAF overhauled should be inspected for proper bearing and contact pattern
adjustment before installation.
• Remove rust protective coating from locating surfaces
• Replace o-ring (Nr. 5)
• Re-install by meshing the spline of the sun gear shaft into the No-Spin (compensating gears) by
 lightly turning at the cardan flange to ease insertion
• Then push together axle beam up to flange location and pay attention to the straight pin (Nr.9)
• Screw on hex.-nuts (Nr.2). Tightening moment is 120+15 Nm
• Install axle into vehicle (connect cardan shaft)
• Fill oil into differential and the planetary drives
• Test-drive and retighten axle mounting bolts

Fig. 3
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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2 Repairs on the Differential

2.2.1 Exchange of Crown Gear / Pinion
(see Fig. 4)
Note!
The crown gear and pinion (Nr.5) can only be exchanged as a matched set and not separately, since the
gears have been mated to one another. The same numbers marked on the crown gear and pinion identifies
the matched set (Engraved with etching pen).
It is advisable to replace all bearings, when doing this sort of repair.
Absolutely necessary are further: Special Assembly Tool Sk 1.90-033/16
Caliper (jaw length 100 mm)
Digital depth gauge with span of min. 120 mm
Adjusting washer (Nr.1 / 11)
• Remove differential (Section 2.1)
• Remove flange (Nr.20)
• Take out differential cage (Nr.3) with crown gear (Nr.5)
• Inspect tapered roller bearing (Nr.2) and (Nr.19) and replace, if necessary
• Loosen pinion nut (Nr.28) and remove, brace cardan flange (Nr.26) and heat to approx. 100° to ease
disassembly
(The loosening moment may reach up to 450 Nm)
• Pull off cardan flange (Nr. 26) and remove pinion (Nr.5) inward
• Remove shaft seals (Nr.24) a. (Nr.23)
• Inspect tapered roller bearing (Nr.2/19) for diff.-cage bearing and (Nr.22/9) for pinion and replace,
if need be. Note adjusting washers (Nr.1/10) at tapered roller bearings (Nr.2a.9). First use always
factory thickness of adjusting washer.
• Loosen hex.-bolts (Nr.8) and press crown gear (Nr.5) off the differential cage (Nr.3)
• Slide new crown gear onto differential cage (Nr.3) and at the same time insert both straight pins
(Nr.6). Tighten new hex.-bolts (Nr.8) (little coating on thread) cross-wise with a torque wrench.
Tightening moment is 115+ 10 Nm.
• Determine thickness of the adjusting washer (Nr. 1) (see section 2.2.1.1).
• If replacing, press selected adjusting washer (Nr.1/10) and bearing outer rings from (Nr.2 and Nr.9)
into differential housing (Nr.15)
• Press bearing inner rings (from Nr.2 and 19) with roller cage onto diff.-cage (Nr.3).
Assembly temperature for bearing inner rings (Nr.2/19) max. 80°.
• Determine thickness of the adjusting washer (Nr. 10) (see section 2.2.1.2)
• Press bearing inner ring (from Nr.9) with roller cage onto pinion (Nr.5).
Assembly temperature for bearing inner ring (Nr.9) max. 80°.
• Press pinion (Nr.5) from inside out and hold against
• Determine thickness of adjusting washer (Nr.11)
• First insert selected adjusting washer(s) (Nr.11), then spacer sleeve (Nr.12) onto pinion (Nr.5)
• Press bearing inner ring (from Nr.22) with roller cage onto pinion (Nr.5).
Assembly temperature for bearing inner ring (Nr.22) max. 80°.
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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

• Install cardan flange (Nr.26) and pinion nut (Nr.28) without Loctite and tighten with 600 Nm
• Check pinion bearing preload with a torque wrench, and if need be, change adjusting washer
(Nr.11).
(Preload: 0.5 - 2.0 Nm for new pinion bearings)
(Preload: 0 - 1.0 Nm for used pinion bearings)
Above numbers are valid only without installed shaft seals and without installed crown gear.
-Document the measured pinion bearing preload-
• Again loosen pinion nut (Nr.28) and clean threads of pinion and nut from all dirt, oil, and inhibitors
• Assemble both shaft seals (Nr.23 and Nr.24) in correct sequence and location with mandrel. Fill the
space between both shaft seals (Nr.23 and Nr.24) to 50% with grease (First shaft seal (Nr.23)
without dust wiper, and seal lip inward, then press on shaft seal (Nr.24) with dust wiper outward).
• Install new o-ring (Nr.25)
• Coat entire diameter and length of thread of pinion (Nr.5) and nut (Nr.28) with Loctite 639
• Screw nut (Nr.28) onto pinion (Nr.5) and tighten with 600 Nm. The final position must be achieved
within 3 to 5 minutes in order for the Loctite to achieve its full potential.
• Check pinion bearing preload with torque wrench and document (Preload: 0.5 - 2.0 Nm).
• Install No - Spin (compensating gears) and install flange (Nr.20) and fasten Special Assembly Tool
(Sk 1.90-33/16) for test purposes with four temporary assembly screws M 12 x 30.
• Check backlash between crown gear and pinion (play 0.15 - 0.25) (see section 2.2.2), if necessary
change adjusting washer (Nr.1) at tapered roller bearing (Nr.2)
• Install differential (see section 2.1)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

Fig. 4

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2. Determining Thickness of the Adjusting Washer (1)

(see Fig. 4 and 7)
• Press in new bearing outer ring (Nr.2) into diff.-housing (Nr.15) until stop, first of all without
adjusting washer (Nr.1)
• Install diff.-cage (Nr.3) with new crown gear (Nr.5)
• Install flange (Nr.20) with new bearing inner ring (Nr.19), and then fasten with Special Assembly
Tool (Sk 1.90-33/16) and four temporary assembly nuts M 12
• Tighten assembly nut (Nr.21) until bearing preload has a friction moment of a approx. 1.0 - 2.0 Nm
at the diff.-cage
• Turn diff.-cage (Nr.3) 2-3 times and straighten tapered roller bearing by tapping out
• Now turn diff.-cage (Nr.3) with crown gear so, that the measuring opening at the flange of the diff.-
cage (Nr.3) is under one of the two large openings of the flange (Nr.20)

Fig. 7

• Calculating thickness (S4) of the adjusting washer (Nr.1)

S4 = D2 + D1 - D3
„D1“ measure with depth gauge (approx. 69)
„D2“ = Target adjusting measurement (engraved on crown gear)
„D3“ = 122,8 (Fixed measurement for Special Assembly Tool a. centre diff. including backlash)

Sample: „D1“ = 68.75 (measured)

„D2“ = 56.20 (reading)
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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

„D3“ = 122.8 (Target measurement)

S4 = 56.20 + 68.75 -122.80 = 2.15
Select next larger 1/10 thickness, which would be 2.2 mm
With this thickness of the adjusting washer there should later be a backlash of 0.2 mm
on hand
• Screw off Special Assembly Tool (Sk 1.90-33/16) and remove diff.-cage (Nr.3)
• Remove bearing outer ring (Nr.2) with suitable inner race puller
• Install selected adjusting washer (Nr.1) and press again bearing outer ring (Nr.2) into position

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2.1.2 Determining Thickness of the Adjusting Washer (10)

Note! By selecting the adjusting washer (Nr.10) the contact pattern adjustment is carried-out

Fig. 8

• Calculating thickness (Se) of the adjusting washer (Nr.10)

Se = L2 - Le - Lr -L1
„L2“ = distance between bearing seat (Nr.35) and centre of the differential.
„Le“ = Target measurement (on pinion face engraved approx. 60.1 to 60.4 mm)
„Lr“ = measure and document pinion gear height. The measurement „Lr“ can vary between 34.5 and
34.9
„L1“ = measure actual thickness of new bearing (Nr.35). The measurement „L1“ can vary between
29.37 and 29.57 (Caliper with at least 100 mm jaw length).
Sample: „Le“ = 60.17
„Lr“ = 34.75
„L1“ = 29.40
„L2“ = 126.97
Se = 126.97 - 60.17 - 34.75 - 29.40 = 2.65
Select next 2/10 thicker washer which would be 2.6 mm

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2.1.3 Pinion Bearing Adjustment

• Clean pinion (Nr.5) and pinion nut (Nr.28) of dirt, oil, and inhibitors
• Coat entire diameter and length of thread of pinion (Nr.5) and nut (Nr.28) with Loctite 639
• Apply wear and seizing inhibiting paste to the contact surface of the nut (Nr.28)
(i.e. Wolfracote SSP from Klüber)
• Thread nut (Nr.28) onto pinion (Nr.5) and tighten with 600 Nm, while supporting cardan flange
(Nr.51). After some tap hammering on the outside of the housing in the area of the pinion bearing to
align the tapered rollers. The final location must be achieved within 3 to 5 minutes in order for the
Loctite to achieve its full potential.
• Check pinion bearing preload with a torque wrench and if need be, correct adjustment.
The pinion bearing may not have any axial play, but should let itself turn with 0.5 to 6.0 Nm. For
used bearings an adjustment value of 0 to 5.0 Nm may apply.
• Check again adjusted bearing preload of the pinion bearing with torque wrench, and if necessary
correct adjustment, and document for later crown gear adjustment.
2.2.1.4 Crown Gear Bearing Adjustment
• Install compensating gear, insert flange (Nr.20) with assembly nut (Nr.21) and fasten Special
Assembly Tool (Sk 1.90-33/16) for test purposes with four temporary assembly nuts M 12
• Tighten assembly nut (Nr.21) by tapping until the friction moment at the cardan flange (Nr.26) is
approx. 0.5 Nm higher than at the pinion bearing adjustment (documented value in section 2.2.1.3)
• Check backlash between crown and pinion (play 0.15 - 0.25), if necessary change adjusting washer
(Nr.1) at the tapered roller bearing (Nr.2).
Note: 0.15 - 0.25 mm at the centre diameter of the pinion (Nr.5)
or 0.3 - 0.5 mm circumference at the cardan flange (Nr.26)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2.1.5 Checking Contact Pattern

• Remove Special Assembly Tool (Sk 1.90-33/16), take out flange (Nr.20) and take out the diff.-cage
(Nr.3)
• Coat flanks from 2 teeth (= 4 tooth flanks) of the crown gear (Nr.5) with thin yellow oil based paint
and reinstall diff.-cage (Nr.3), flange (Nr.2) with temporary assemble nut (Nr.21), and Special
Assembly Tool (Sk 1.90-33/16). Turn pinion, so that the contact pattern is marked by the paint.
• Remove Special Assemble Tool (Sk 1.90-33/16), take out flange (Nr.20) and diff.-cage (Nr.3) and
assess contact pattern. With proper adjusting washer (1) thickness a contact pattern as per Fig. 11
should be achieved, otherwise select a new adjusting washer (Nr.10) at the pinion bearing (see
section 2.2.1.2).
• If contact pattern is correct , screw on temporary assembly nut (Nr.21) and clean the threads of
flange (Nr.20) and new nut (Nr.21) of dirt, oil, and inhibitors.
• Coat both threads at the entire diameter and length with Loctite 639. Tighten assemble nut (Nr.21),
until the friction moment of the pinion is again approx. 0.5 Nm higher than without the crown gear.
The final position must be achieved within 2 to 5 minutes in order for the Loctite to achieve its full
potential.

Fig. 9 Fig. 10

If there is a contact pattern as per Fig. 9 or 10, than by shifting the pinion with help from a
change in the adjusting washer (Nr.1) a contact pattern as per Fig. 11 is advisable to achieve. By
changing the thickness of the adjusting washer (Nr.10) and turning of the temporary assembly
nut (Nr.21) the crown gear can be shifted likewise as per Fig. 9 or 10.

CAUTION: During the adjustment process, always

pay attention to the proper preload for the bearings
(Nr.2) and (Nr.19). Likewise, when turning the nut
(Nr.21) pay attention to the correct backlash.
Always wash off old oil paint from previous
adjustment attempts.

Fig. 11

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.2.2 Exchange of Differential Cage (No - Spin Compensator)

(see Fig. 4)
Note: Both halves of the diff.-cage (Nr.3) can only be exchanged together, note orientation markings and
identification. The No-Spin Compensator should not be repaired, it should only be exchanged as a
complete unit.
• Remove differential (see section 2.1)
• Detach flange (Nr.20)
• Take out differential cage (Nr.3) with crown gear (Nr.5)
• Inspect both tapered roller bearings (Nr.2 and Nr.19) and replace if necessary
• Loosen hex. bolts (Nr. 8) and pull crown gear (Nr.5) from differential cage (Nr.3)
• Remove hex. bolts (Nr.30) and open differential cage
• Remove No-Spin Compensator as a unit. Inspect components and replace if necessary.
• No adjustment of the differential cage must be performed
• Screw the differential cage with eight new coated hex. bolts (Nr.30) together.
Tightening moment for hex. bolts (Nr.30) is 70+5 Nm.
• Press on both tapered roller bearings (Nr.2 and Nr.19) and during replacement also renew bearing
shells in the differential housing (Nr.15). Observe the adjusting washer (Nr.1) at the tapered roller
bearing (Nr.2).
• Install compensating gear and insert flange (Nr.20) and for test purposes fasten Special Assembly
Tool (Sk 1.90-33/16) with four temporary assembly nuts M 12.
• Check backlash between crown gear and pinion (play 0.15 - 0.25), if necessary change adjusting
washer (Nr.1) at the tapered roller bearing (Nr.2).
Note: 0.15 - 0.25 mm at the centre diameter of the pinion (Nr.5)
or 0.3 - 0.5 mm at the circumference of the flange (Nr.28)
• Check contact pattern (see section 2.2.1.5).
• Remove Special Assembly Tool (Sk 1.90-33/16)
• Install differential (see section 2.1)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.3 NoSpin
2.3.1 How to test the NoSpin
Step 1: Raise driving axle from floor so that
tires are completely free.
Step 2: Place transmission in gear.
Step 3: (See illustration in panel to left).
With an assistant on the reverse side, start test
by rotating both wheels in a forward direction as
far as possible (normally, both wheels will be
stopped after rotating only a few inches).
Step 4: (See illustration in panel to left).
Which one person firmly holding the right
wheel forward (against the stop), rotate the left
wheel rearward while listening for a regular
indexing or clicking sound (the right wheel
must be held firmly against the stop or left
wheel will not disengage freely).
Step 5: (See illustration in panel to left).
Rotate both wheels rearward as far as possible
(again, both wheels will be stopped after
rotating only a few inches).
Step 6: (See illustration in panel to left).
With an assistant on the reverse side firmly
holding the right wheel in a rearward position
(against the stop), rotate the left wheel forward,
again listening for an indexing or clicking
sound. (Again, the right wheel must be held
firmly against the stop or the left wheel will not
Fig.12: Illustration to test the NoSPIN disengage freely).

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

REPEAT STEPS 3, 4. And 6 (See Steps 3B,

4B, and 6B illustrated in panels to right)
starting with right wheel, after again rotating
both wheels forward as far as possible.
IF PROPERLY INSTALED, the free rotation
of each wheel in both directions will produce
a slight indexing of clicking sound.
IF EITHER WHEEL DOES NOT ROTATE
OR CAM FREELY IN BOTH
DIRECTIONS, recheck each step of the
installation procedure. Also check both hand
and foot brakes for drag caused by improper
adjustment. Check again to be sure that all
thrust washers have been removed.

Fig.13: Illustration to test the NoSPIN

2.3.2 How the NoSPIN operates
The NoSPIN Differential performs two key functions:
1. It prevents wheel-spin when one wheel loses traction - a condition that would probably stall a
vehicle equipped with a conventional differential.
2. It compensates for differences in wheel travel which occur when turning or traveling over
uneven ground.
When a vehicle is being driven in a straight-forward direction, the NoSPIN Spider and
Driven Members are fully engaged and allow equal torque to be distributed to both rear
wheels. Gear teeth on the Spider and Driven Members are so positioned that neither
wheel can turn more slowly than the ring-gear speed. If one wheel should lose traction
momentarily by rolling onto ice or snow or over a soft shoulder of the road, the
opposite wheel, which still has traction, continues to pull the vehicle until the traction is
regained by both wheels.

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

In normal operation when the right wheel passes over an obstruction, or if the vehicle
makes a left turn, the right wheel must travel faster and farther than the left wheel.
When this situation occurs, the NoSPIN automatically allows for the difference in
wheel travel. The left Driven Member remains completely engaged with the NoSPIN’s
spider and continues to drive the vehicle. The right Driven Member automatically
disengages from the spider allowing the outer wheel to free wheel around the corner.
When the vehicle returns to the smooth surfaced straightaway the spider automatically
re-engages the left Driven Member and both wheels again drive the vehicle.

Fig.14: Illustration by driving a bend Fig.15 Illustration of NoSPIN as unit

Fig.16: Illustration of single parts in the NoSPIN

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.3 Planetary Drive

2.3.1 Exchange of Complete Planetary Cage
(see Fig. 17 and 18)
• Jack vehicle up and secure
• Remove wheel.
• Drain oil (Section 1.4.2.3)
• Loosen hex. bolts (Nr.33)
• Pull off complete planetary cage (Nr.7)
• Replace o-ring (Nr.25) and insert into the groove of the wheelhub (Nr.26)
• Assemble complete new planetary cage (Nr.7).
For this, bring teeth of the sun gear shaft (Nr.17) and the 3 planetary gears to meshing location.
Then under light turning, slide on planetary cage until the planetary gears mesh into the crown gear
(Nr.15). Afterwards, slide planetary cage (Nr.7) on all the way.
• Insert hex. bolts (Nr.33). Tightening moment is 79 Nm
• Fill oil (Section 1.4.2.3 -Planetary Drive)
• Install wheel
• Lower vehicle

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

Fig. 17
2.3.2 Exchange of Sun Gear Shaft
• Remove planetary cage (Nr.7) (see section 2.3.1)
• Remove sun gear shaft (Nr.17) from axle stub (Nr.31)
• Install new sun gear shaft (Nr.17) and ease installation by light turning the sun gear shaft into the
grooved profile of the No Spin Compensator
• Install planetary cage (Nr.7) (see section 2.3.1)
• Check adjustment of compression stud (see section 2.4.4).

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

Fig. 18
2.3.3 Exchange of Planetary Gears
• Remove planetary cage (Nr.7) (Section 2.3.1)
• Place planetary cage (Nr.7) with the opening upward
• Loosen 3 hex. bolts (Nr.19)
• Pull out planetary cage - inner part (Nr.14) with puller
• Remove complete thrust washer (Nr.13), planetary gear (Nr.10) with both needle bearing rings
(Nr.11) and thrust washer (Nr.9). Inspect the parts and if necessary replace the parts.
• Insert thrust washers (Nr.9) with the lip showing inward
• Slide on both needle bearing rings (Nr.11) and install planetary gear (Nr.10)
• Install shear sleeve (Nr.18) and check completeness respectively
• Insert thrust washer (Nr.13) with the lip showing towards the outside
• Press on planetary cage (Nr.14) and screw on with new and coated hex. bolts (Nr.19). Tightening
moment is 115 Nm.
• Check the free floating of the planetary gears (Nr.10) and axial play (min. 0.3 mm)
• Install now complete planetary cage (Nr.7) (see section 2.3.1)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.3.4 Exchange of Planetary Pins

• Remove planetary cage (Nr.7) (Section 2.3.1)
• Place planetary cage (Nr.7) with the opening upward
• Loosen three hex. bolts (Nr.19)
• Fasten pulling plate (Sk 4.90-040) with three temporary assembly bolts M 8x25 to the three
planetary bolts (Nr.25) and pull out with centre bolt the planetary pin (Nr.12) and planetary cage -
inner part (Nr.14)
• Remove complete the thrust washer (Nr.13), planetary gear (Nr.10) with both needle bearing rings
(Nr.11) and thrust washer (Nr.9). Inspect the parts and if necessary replace.
• Install new planetary pins (Nr.12) with new tolerance ring (Nr.8)
• Insert thrust washers (Nr.9) with the lip showing inward
• Slide on both needle bearing rings (Nr.11) and insert planetary gear (Nr.10)
• Install shear sleeves (Nr.18) and check completeness respectively
• Install thrust washer (Nr.13) with the lip showing towards the outside
• Press on planetary cage (Nr.14) and screw on with new and coated bolts (Nr.19). Tightening
moment is 70+7 Nm.
• Check the free floating of the planetary gears (Nr.10) and axial play (min. 0.3 mm)
• Install now complete planetary cage (Nr.7) (see section 2.3.1)
2.3.5 Exchange of Crown Gear Carrier
• Remove planetary cage (Nr.7) (Section 2.3.1)
• Remove snap ring (Nr.23)
• Replace ring gear (Nr.15)
• Reinsert snap ring (Nr.23).
Note:
The ring gear should have now a radial play of approx. +/- 0.4 mm
• Install planetary cage (Nr.7) (Section 2.3.1)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.4 Wheel Bearing

(see also Fig. 17 and 18)
2.4.1 Wheel Bearing Exchange
• Remove planetary cage (Nr.7) complete (Section 2 3.1 )
• Disassemble sun gear shaft (Nr.17) (Section 2. 3.2)
• Screw off groove nut (Nr.21)
For this, heat groove nut M 50x1.5 (Nr.21) to approx. 150°C (i.e. with soldering torch) and loosen
with Special Socket Wrench (Sk 3.90-054 /07.73.028.92032)
• Remove crown gear carrier (Nr.22) with ring gear (Nr.15)
• Pull off wheel hub (Nr.26) and outer wheel bearing (Nr.24) simultaneously from the axle stub
(Nr.31), with an appropriate extractor
• Remove axial face seal (Nr.29 / Fig. 13) from wheel hub (Nr.26) and axle stub (Nr.31)
• Inspect sealing area at axle stub (Nr.31) and wheel hub (Nr.26), and if necessary replace axle stub
(Nr.31) or wheel hub (Nr.26)
• Place a two-claw-puller at axle stub ring (Nr.30) and pull off bearing inner ring of the inner wheel
bearing (Nr.28) simultaneously from axle stub (Nr.31)
• Press bearing outer rings of the wheel bearings (Nr.24 a. Nr.28) from the wheel hub
• Install new bearing outer rings (Nr.24 a. Nr.28) into the wheel hub (Nr.26)
• Install axle stub ring (Nr.30) with new bearing inner ring of bearing (Nr.28) onto the axle stub
(Nr.31), when needed use assembly sleeve and press hard against stopping face of axle shaft.
Assembly temperature for bearing inner ring (Nr.28) max. 80°.
• Install new axial face seal (Nr.29 / Fig. 13) into wheel hub (Nr.26) and axle stub (Nr.31) with
proper tools (see section 2.4.3)
• Clean thread M 50x1.5 of the axle stub (Nr.31) and groove nut (Nr.21) of dirt, oil, and inhibitors
• Centrally insert wheel hub and assemble heated bearing inner ring (Nr.24) completely onto axle
stub (Nr.31), when needed use assembly sleeves
• Coat end faces of the crown gear carrier (Nr.22) with Klüber-Paste Wolfracote SSP
• Insert crown gear carrier (Nr.22) with ring gear (Nr.15)
• Adjust wheel bearing (see section 2.4.2) and tighten groove nut (Nr.21) with Special Socket
Wrench (Sk 3.90-054 / 07.73.028.92032)
• Insert sun gear shaft (Nr.17), to ease meshing lightly turn sun gear shaft forth and back for insertion
into profile of No-Spin Compensator. Or install with complete planetary cage together (see section
2.3.2)
• Reassemble planetary cage (Nr.7) (see section 2.3.1)

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.4.2 Wheel Bearing Adjustment

• Coat end faces of crown gear carrier with Klüber-Paste Wolfracote SSP
• Clean thread M 50x1.5 of axle stub (Nr.31) and groove nut (Nr.21) of oil, dirt, inhibitors, and
adhesive residue
• Coat entire diameter M 50x1.5 and length of axle stub (Nr.31) and groove nut (Nr.21) with Loctite
639.
• Tighten groove nut (Nr.21) so far until the friction moment is approx. 7.5 Nm - 10.0 Nm at the
wheel bearing. Align roller cage and wheel bearing, for this turn wheel hub 1-2 x in both directions
and by tapping with a rubber mallet on the outside of the wheel hub (Nr.26) and crown gear carrier
(Nr.22)
• The final location of the groove nut (Nr.21) must be achieved within 2 -5 minutes, in order for the
Loctite to achieve its full potential
2.4.3 Exchange of Axial Face Seal
Refer to sections 2.4.1 and 2.4.2

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 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

2.4.4 Check Thrust Stud Adjustment

• For this measure distance (l4) between wheel hub flange surface (Nr.26) and end face of sun gear
shaft (Nr. 17) and distance (l5) between flange surface of planetary cage (Nr.7) and thrust surface of
the thrust stud (Nr.16) with depth gauge.
Axial play l5 - l4 must be at least 0.5 mm (min. 0.2 to max. 3.0 mm).
• If the measured or calculated axial play is outside of those values, the thrust stud (Nr.16) has to be
reworked or replaced.

Fig. 19 Fig. 20

2.4.5 Exchange of the Axle Stub

(see Fig. 17 and 18)
08.99.003.00027 Seite 26 von 27
 Service and Repair Manual
Type : FL 22/0 Planetary Rigid Axle for Microscoop 100
Name : SAP 4302.101
Valid as of Factory Nr.: 01
Date of Issue : 11/10/04

• First of all perform disassembly as per 2.4.1

• After loosening the hex. bolts (Nr.34) remove complete axle stub (Nr.31)
• Insert new o-ring (Nr.35) at the axle stub (Nr.31)
• Insert both straight pins (Nr.59) into the axle beam (Nr.101).
Install complete preassembled axle stub (Nr.31) with hex. bolts (Nr.34) onto the axle beam
(Nr.101). Tightening moment is 290 Nm.
• Continue assembly as per section 2.4.1
• Reinstall wheel
Revisions reserved
Neunkirchen on the 05.03.1997

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