Driveline & Axle System.pptx

Technician Level 2 – Module 3
Drive & Axles System LCV

Introduction
 Participant Name
 Dealership Name
 Location
 Experience in Tata Motors (In years & months)
 Specialization in which Models / Aggregates
 Hobbies
7/27/2022 TML 2

Program Objectives
At the end of this module the participants will be able to:
 Understand the construction of Front & Rear Axle of LCV range of Vehicles
 Perform Removal, Dismantle & Refitting of Front & Rear Axles of LCV Vehicles
 Perform Overhauling of Rear Axle -407/709 Type
3

Program Agenda
Front Axle System
 Front Axle -709 Type
– General Information
– Removal of Axle Components
– Disassembly of Axle Components
– Inspection
– Assembly of Axle Components
– Important Adjustments & Settings
Rear Axle System
 Rear Axle -407/709 Type
– General Information
– Removal of Rear Axle
– Disassembly of Rear Axle
– Inspection and Checking of Components
– Assembling Crown Wheel & pinion
– Important Adjustments & Settings
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(Front Axle & Rear Axle)
Introduction to Driveline & Axle Systems - LCV
7/27/2022 TML 5

General Information
Front Axle 709/909 Type
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Front Axle - Introduction
 The front axle is designed to transmit the weight of the automobile from the springs to the
front wheels, turning right or left as required.
 Front axle includes the axle-beam, stub-axles with brake assemblies, steering components
and suspension components
 The front axles are generally dead axles, which does not transmit power. The front wheel
hubs rotate on antifriction bearings of tapered-roller type on the steering spindles, which are
an integral part of steering knuckles. To permit the wheels to be turned by the steering gear,
the steering spindle and steering knuckle assemblies are hinged on the end of axle.
7/27/2022 TML 7

Front Axle – 709/909 Type – General Information
The FA -709/909 Type is Dead Front Axle with
Reverse Elliot Type I Beam Design
Reverse Elliot Type:
 The reverse Elliot front axles have hinged
spindle yoke on spindle itself instead of on
the axle. The forked portion is integral with
the steering knuckle.
Elliot Type :
 In the Elliot type front axles the yoke for
king spindle is located on the ends of I-
beam. The axle ends are forked to hold the
steering knuckle extension between them
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Reverse Elliot Elliot
Reverse Elliot Type Axle

Front Axle – Main Parts
7/27/2022 TML 9

Front Axle – Main Parts
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Front Axle – Stub Axle Parts
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Kingpin
Kingpin Bore

Front Axle – Technical Specification –FA-709/909
 Technical Specification
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Sl. No Description 709 909 Units
1
Stub axle parent bore for king pin
bush
35.031 – 34.969 37.031 – 36.969 mm
2 King pin bush outside diameter 35.076 – 35.060 37.076 – 37.060 mm
3
End play between & front axle
beam
0.025 – 0.10 0.025 – 0.10 mm
4
Shims for stub axle axial play,
available in thickness of
0.05, 0.10, 0.15, 0.5,
0.8, to 1.7 in steps of 0.1
mm
0.05, 0.10, 0.15, 0.5,
0.8, to 1.7 in steps of
0.1 mm
mm
5
Inner bearing seat diameter on
stub axle
54.990 – 54.977 54.990 – 54.977 mm
6
Outer bearing seat diameter on
stub axle
34.991 – 34.975 39.991 – 39.975 mm

 Technical Specification
 Front Wheel Alignment Data
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Sl. No Description 709 909 Units
7 Inner bearing bore diameter on hub 94.962 – 94.922 99.962 – 99.927 mm
8 Outer bearing bore diameter on hub 79.968 – 79.938 89.962 – 89.927 mm
Description 709/909
Toe in (measured on wheel rim)
0 – 3 mm
0 – 25 mm
King pin inclination 9° 30’ + 10’
Caster For Power Steering - 3° ± 30
For Mechanical Steering - 1° ± 30
Wheel Lock Angle 48° for 709, 909, 712 and 912

 Standard & Repair Sizes of Kingpin Bores
 Axial Play of Front Hub Bearings : 0.01 to 0.06 mm
7/27/2022 TML 14
King pin dia. mm
King pin bore in stub axle bush
mm
King pin bore in front axle
beam mm
709 909 709 909 709 909
Normal
30.037-
30.028
30.037-
30.028
30.037-
30.028
30.037-
30.028
31.021 –
30.000
32.025 –
32.000
Normal 1
30.305-
30.295
32.305-
32.295
30.364-
30.325
32.364-
32.325
30.292 –
30.267
32.292 –
32.267
Repair 1
30.645-
30.634
32.645-
32.634
30.697-
30.658
32.697-
32.658
30.625 –
30.600
32.625 –
32.600
Repair 2
31.006-
30.995
33.006-
33.995
31.064-
31.025
31.064-
33.025
30.992 –
30.967
32.992 –
32.967

Front Axle -709/909- Application
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TATA 709
TATA 909

FA-709/909 Type
Front Axle Overhauling
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 Removal of Front Axle from the Vehicle
 Inspection of Front Axle
Removal of Front Axle – 709 Type from the Vehicle
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Removal of Front Axle
from the Vehicle
– 709 Type

 Removal of Front Brake Drum
 Removal & Disassembly of Front Wheel Hub
 Inspection of Brake Drum & Hub Components
 Removal & Dis assembly of Stub Axle
 Inspection, Assembly and Installation of Stub Axle
Please follow the reverse order of disassembly while
assembling/refitting the Axle Assembly on to the
Vehicle
Please Carry out Wheel Alignment as per the
Specification
Removal & Assembly of Wheel Hub & Stub Axle
Components
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Removal & Assembly of
Wheel Hub & Stub Axle
Components-709 Type

Important Adjustments & Settings
Adjustment of Stub Axle Axial Play:
 Place a magnetic stand on the axle beam
 Measure end play between stub axle &
front axle beam end boss.
 End Play can be reduced by increasing the
thickness of the adjusting shims and vice
versa
 Select the correct shims to give an end play
as specified ( 0.025 to 0.010mm)
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Adjustment of Front Hub Axial Play: All
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Step - 1 Step - 2 Step - 3
Using torque, loose the lock nut. Using puller take out the hub.
Take out bearings and remove all
old grease, clean the bearing etc.
Measure shim of 2.5mm & set the
hub without grease, measure the
hub play by moving hub. Note and
take out hub.
Calculate new shims pack to achieve
specified hub play and re-install hub
with new shims and filling specific
qty of grease. Torque the lock nut.
Hub play to be measured &
adjusted using dial gauge with
special tool or magnetic stand and
dial gauge.

Front Axle Hub play integral hub with drum
(Magnetic Stand)
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Open the cover and using special
tool take out split nut
Using special tool, take out hub
Step - 4
Fit the bearing and hub on stub
axle using special tool
Measure hub play after fixing the magnetic stand of the dial gauge on
suitable mounting surface. Measure the hub play

Xenon
Front Axle Live
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Spicer Live Front Axle - Xenon
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Front Axle Shaft Removal- Spicer
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• Put chocks at rear wheels
• Remove front wheels, disconnect brake hose, caliper assembly
• Release torsion bar load fully
• Disconnect tie rods
• Wrap axis shaft with layers of tape & use a wire to attach shaft to frame
• Disconnect top & bottom suspension ball joints
• Pry out with a big screw driver axle shaft at side gear end
• Remove wheel end with CV shaft after removing above wire

Removing the wheel end components
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Separating wheel end from CV shaft
• Remove free running hub after removing Its fasteners
• Remove snap ring from axle shaft
• Remove washer & outer, inner brake assembly (hub lock components)
• Remove axle shaft
Caution: While loosening outer nut take care not to break pin on inner nut
Assembly of wheel end
• Torque Inner nut to 6.8 kg-m
• Rotate hub & back off inner nut 90 degrees maximum till pin on nut aligns with closest
hole In lock washer
• Torque outer nut to 20.3 to 30.5 kg-m
• Wheel bearing play should be 0.00 to 0.1 mm

Overhaul of spindle assembly
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• Remove inner bearing from spindle using Adaptor ring (part no 2698 5890 3516), press (part no 2698 5890 3515)
and adaptor plug (part no 2704 5890 3329).
• Use adaptor (part no 2704 5890 3326) to remove bearing cage on spindle
• Remove the 6 nuts of brake dust shield and spindle
• Remove spindle from knuckle by tapping
• Remove spindle needle bearing and seal using Bearing puller (part no 2704 5890 3328)

Front Axle Shafts
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RHS Shaft with male splines on DOJ
LHS Shaft with female splines on DOJ
• Each LH & RH half shaft has following 2 types of joints
• Fix Rzeppa joints : This is used on the wheel end
• Double offset joints (DOJ) : This is used near center section (differential)
• Rzeppa joint is built with arch grooved outer & inner race and a cage with 6 balls
• Arch grooves of the Rzeppa joint allow wheel up/down movement
• DOJ Is similar except with straight grooves to allow change in length
• LH half shaft fits onto axle shaft & RH Into differential side gears

Overhauling of Rzeppa Joint
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Dismantling
• Mark position of small end of the boot on shaft for reassembly
• Cut & discard boot & clamp
• Clear grease to see snap ring of inner race
• Expand snap ring & remove shaft by topping on outer race
• Use ball assy. tool (part no 270458903333) to tilt inner race
from side to side in star pattern & remove all balls from the
cage
• Remove Inner race & cage
• Pivot inner race & remove from cage
Assembling
• On side of shaft having 1 circlip groove, fit boot & clamp (w/o
tightening)
• Reverse above assembly procedure
• Install new circlip in inner race
• Fully fill lithium grease
• Push CV joint onto shaft till 'click' of circlip Is heard -pull to
confirm
• Use clamp crimper (part no 270458903332) to clamp boot on
CV joint
• Align boot marks done at the 1st step and tighten clamp

Overhauling of Double Offset Joint
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Dismantling
Mark position of boot for reassembly
Cut & discard boot & clamp
If grease Is contaminated, CV joints needs replacement
Clear grease to remove retainer ring In outer race using screw
driver
Remove outer race
Using pliers (part no 270458903331) expand & slide back the
Inside circlip
Remove outer circlip using plier 2704 5890 3330
Assembling
On side of shaft having 2 circlip grooves, fit boot & clamp (without
tightening)
Assemble inner race, cage & balls
Install inner race assembly & 2 types of new circlip on shaft
Pack 2/3rd of specified amount of grease in outer race &
remaining inside boot
Install outer race assembly over ball & cage assembly
Push back inner race with balls & install large retaining ring
Use crimper (part no 2704 5890 3332) to crimp clamp on CV joint
Align boot marks as 1st step and tighten clamps.

Winger Front Axle (Transaxle)
 Dismantling and assembling process of
Winger
Step 1:
 Winger is front wheel drive vehicle and
having drive shafts for driving front wheels.
 Winger front stub axle bearing is fitted on
stub axle with double bearing arrangement
as shown.
Step 2:
 Jack up the vehicle, remove the tyres.
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Step - 3
 Remove locking pin between CV shafts and
axle shafts. Use a small pin & tap out the
pin from the smaller hole side.
Step - 4
 Support the brake disc suitably.
 Remove steering ball joint assy. from front
hub.
 Tilt the front stub axle , pull & remove the
CV shaft from transaxle shaft side & then
from hub.
 Remove nylock nut & dismantle front hub
from lower wish bone.
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Step - 5
 Hold the front stub axle in vice suitably &
unscrew the brake disc mounting bolts.
 Use 3 jaw puller & pull the stub axle up.
Press out the unitised bearing.
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407/709/909/1109
Wheel Alignment – Manual
7/27/2022 TML 33

Adjustments in LCV / MCV Front Axle Toe-in
1. Place toe-in gauge in front of front wheels. Adjust height of toe-in gauge arms to center of
wheel on both sides. Now adjust toe-in gauge width such that pin on one arm and gauge
spindle on other touch edges of wheel rim.
2. In this position set gauge such that pointer reads zero (0). Mark both wheel rims with chalk
at the points where pin and gauge spindle have touched.
3. Pull out spindle on gauge and lock in end position. Remove toe in gauge.
4. Move vehicle forward until chalk marks are rotated by 1800(now chalk marks are at rear).
Place toe-in gauge behind front wheels. Do not readjust width of toe in gauge. Move
complete toe in gauge such that pin on one arm touches rim at the chalk mark.
5. Unlock gauge spindle and let it touch rim at other chalk mark. The pointer on RHS indicate
toe-out and on LHS toe-in as seen from front of the vehicle.
6. If toe-in does not correspond to specified value adjust length of tie-rod by loosening tie-rod
clamps at both ends.
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Adjustments in LCV / MCV Front Axle Toe-in
7/27/2022 TML 35

Adjustments in LCV / MCV Front Axle Camber and
Caster Angle
Camber Angle:
 Camber angle is not adjustable in rigid suspension axle. The correct setting of hub play gives
correct camber angle.
 It is measured with the help of gauge as shown:
– Keep the wheels straight ahead position
– Adjust two arms at end of wheel rim and then mark A & B at opposite side on tyre.
– Note reading on St. Move the wheels 1800 and again note reading.
– Average of two readings will indicate caster angle
7/27/2022 TML 36

Adjustments in LCV / MCV Front Axle Camber and
Caster Angle
Caster Angle:
 Caster angle is measured with the gauge shown in fig.
 Keep wheels straight ahead position and note reading on N side.
 Steer the wheels 200 out side and again note reading.
 Difference between the two readings shows the caster angle.
 Caster Plate is given at the bottom spring for caster angle.
7/27/2022 TML 37

Checking Caster, Camber & King Pin Inclination (KPI)
with magnetic type gauge
1. Park the vehicle, place front wheel straight on turn
table. Remove front hub cover.
2. Place the magnetic gauge in centre of the spindle
such that “0” level is indicated on sprit gauge.
3. Angle indicated by bubble on camber scale will
indicate camber angle of that wheel.
4. To check the caster angle and KPI, turn the front
wheel 200 outward. Set respective bubbles of
Caster and KPI scales at “0” position.
5. Turn the wheels 200 inward, reading on caster
and KPI scales as indicated by the air bubbles will
indicate caster angle and KPI of the that wheel.
6. If camber is incorrect, check and adjust hub play. If
caster is incorrect, adjust with the help of caster
plate.
7. If KPI or camber is incorrect even after adjustment
of hub play, check for bend in I beam.
7/27/2022 TML 38

Adjustments in case of Xenon
Camber Adjustment Shims
 Adding shims reduces camber and vice
versa.
Caster Adjustment Shims
 Adding Caster shims in rear side of top
wishbone reduces caster.
 Adding Caster shims in front side of top
wishbone increases caster.
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Adjustments in case of Xenon
Toe Adjustment
 Toe in adjusted by varying the length of tie rods after loosening hex nuts.
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Toe Adjustment
Steering Tie rod

Adjustments in case of 207
Caster & Camber
 Caster Angle Adjustment:
– While adjusting camber angle nobody should sit inside the vehicle.
– To adjust castor angle loosen nut of lower wishbone Front arm eccentric bolt.
– Turn the bolt to get specified castor angle. Retighten nut to 14 mkg. (Wheel should be parallel to
the frame.)
– If specified caster angle is not achieved, then shims are added / removed to get desired caster
angle.
– To adjust the castor angle through shims, add or remove the shims only from one side of the top
wishbone spindle. Adding the shims at the rear side of the spindle will increase the castor and
adding the shims at the front side of the spindle will reduce the castor.
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Adjustments in case of 207
Caster & Camber
 Camber Angle Adjustment:
– During adjusting camber angle nobody should sit inside the vehicle.
– To adjust camber angle, loosen nut of lower wishbone rear arm eccentric bolt.
– Turn the bolt to get specified camber angle. Retighten nut to 14 mkg. ( Wheel should be parallel to
the frame.)
– If specified camber is not achieved through the eccentric bolt, shims should be added or removed
from the top wishbone spindle. The shims should be added or removed from both the sides i.e.
front & rear bolt of top spindle.
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Steering parameters
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Model Steering Type Caster Camber Toe in Wheel Lock Angle
207 Mechanical 3 deg+ 30'
0 +/- 10'
0 +/- 1
33+2
207 Power 2 deg+ 30'
0 +/- 10'
0 +/- 1
33+2
407 SFC / LP Mechanical 1 deg 30' +/- 30'
1 deg +/- 30'
0 - 3 41 deg + 1 deg
407 SFC / LP / LPT Power 2 deg 30' +/- 30'
1 deg +/- 30'
0 - 3 41 deg + 1 deg
709 SFC / LP / LPT Mechanical 1 deg +/- 30'
1 deg +/- 30'
0 - 3 44 deg - 2 deg
709 SFC / LP / LPT Power 3 deg 30' +/- 30'
1 deg +/- 30'
0 - 3 48 deg - 1 deg
909 LPT Mechanical 1 deg +/- 30'
1 deg +/- 30'
0 - 3 48 deg - 1 deg
909 LPT Power 3 deg 30' +/- 30'
1 deg +/- 30'
0 - 3 48 deg - 1 deg
MCV Power / Variable 1 deg +/- 30'
1 deg +/- 30'
1 - 3
38 deg + 1 deg
42 deg for LPO
HCV Power 1 deg +/- 30'
1 deg +/- 30'
1 - 3
38 deg + 1 deg
Right
30 deg + 1 deg
Left

Do’s & Don’ts
1. Vehicle should be parked on flat surface during Wheel alignment checking & setting.
2. In case of abnormal tyre wear, hub play, brake grabbing and wheel alignment to be checked.
3. Always use special tools / machine for checking & servicing.
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407/709 Type
Rear Axle System
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Rear Axle System- LCV – Layout
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Tandem Axle
(No drive)
Banjo Live
Rear Axle

Rear Axle System- LCV - Introduction
LCV range of vehicles employ three types of Axles:
7/27/2022 TML 48

Rear Axle System - Types
Salisbury Type Rear Axle
 Differential assay can not be removed in
assemble condition. Axle beam consists of
3 piece.
Banjo Type Rear Axle
 Differential assay can be removed from
beam. Axle beam is single piece.
7/27/2022 TML 49
Tube pressed Carrier housing
Beam Carrier housing

Rear Axle System - Types
Semi Floating Axle
 One hub bearing is on axle shaft & another
bearing on differential carries load and
transmit torque.
Full Floating Axle
 Axle shaft does not carry load and only
transmits torque.
7/27/2022 TML 50
Semi Floating Axle
Axle shaft is free
Axle shaft
with bearing

Rear Axle System- Banjo Type
A Banjo Differential has the gear set built into a removable centre in the rear axle housing.
 Note that the differential centre is held in the axle housing by a series of studs that look like
the drum tuning keys on a banjo.
 Advantages:
– Easy of Repair , Replace & maintain
– More GVW of the Vehicle Because of More RAW
– Easy On Site Repair Work
7/27/2022 TML 51

Rear Axle System- Salisbury Type
 A Salisbury Rear Axle solves the rotating center that Banjos have by placing the carrier
bearings in the axle housing rather than in the removable center.
 The differential is built into the axle rather than into a removable section.
 Advantages
– Low Cost
– Easy To Manufacture
 Dis Advantages
– On site repair is difficult.
– Low Load Taking Capacities hence applicable to Low GVW Vehicles.
7/27/2022 TML 52

Rear Axle System- Application in LCV
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Model
Axle Type
Dead Axle Spicer 407 RA 104 1009 1109 Type RA 1055 RA 1068
Winger 
Xenon, 207 Di 
1109 
Ultra truck 912 
Ultra truck 812 
Ultra bus 9.6T, 8.5T 
Ultra bus 7.5T 
709/712 
LP 909/912 
LPK 909 
SK 709 
SFC / LP / LPT 407 

 Banjo Type – Fully Floating (709 Type)
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TATA 709
TATA 909

 Salisbury Type – Semi Floating
 Salisbury Type – Fully Floating (407 Type)
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Tata -207 DI Tata - Xenon
Tata -407 Tata – 709 SK

7/27/2022 TML 56

Rear Axle System – LCV - General Information
7/27/2022 TML 57
Vehicle
model
Rear axle /Ratio
CW/P
Ratio
Oil Capacity Hub grease Hub Play Backlash Axle wt
Xenon/207
Salisbury type
Spicer
51/11 2.2 L No grease Inbuilt 0.12 - 0.2 mm max 95 kg
LP/LPT/SF
C 407 Turbo
/ EX -Twin
tyre/410
RA 407 Type
37/8 or
35/9 RA
104 type -
31/8
1.5 L 225 gms 0.01 - 0.08 0.2 - 0.26 227 kg
LP/LPT/
SFC 709
Turbo EX
RA 104
Salisbury
31/8 2.75 L 375 gms 0.04 - 0.1 0.24 - 0.30 287 kg
LPT/LP
1109 Turbo
Ex
RA 1009 Banjo
43/11
41/11
41/7
8.5 L 700 gms 0.02 - 0.04 0.21 - 0.27 460 kg
LP1512TC RA108 RR 41/7 8.5 L 450 gms 01 - 06 mm 0.21 - 0.27 mm 350 kg
SK1613/
2515/2518
RA-109RR 41/6 14 L 650 gms 0.04-0.12 0.28-0.34 679 kg
Ultra Truck RA 1068 34/7 4 L
CONSIST ENCY-3,
Y-3, SS 6805
375 gms
0.04-0.12 0.24-0.30 285 kg

Rear Axle Identification Number
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752 01 1 YY 1 23401
Basic Model
Variation in Basic Model
Year of Production
Plant Location
CWTP Ratio
Sr. Number
Identification Description
752 Basic Model - 407
01 SFC Twin Tyre
1 Crown Wheel to Pinion Ratio 34/7
YY Model Year
1 Jamshedpur
23401 Serial Number of Production

Rear Axle System - Components
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Rear Axle System – Differential Components
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Bevel Pinion

Rear Axle System – Wheel Hub Components
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Rear Axle Components – Types of Wheel Hubs
Hub with brake drum 407 Rear Hub 709
7/27/2022 TML 62
Lock nut Lock ring

Rear Axle System – RA 108 ( Ultra Truck)
 This is a banjo type rear axle having the different type of carrier housing as shown. This is a
split type housing and pinion depth is set by adjusting the shims as shown.
 Pinion bearing having set preload with spacer
7/27/2022 TML 63

Rear Axle System – Spicer ( 207 / Xenon)
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Differential Assy
Axle shaft New HD Axle Axle shaft Old Axle Single Bearing

Xenon & 407/709 Type
Rear Axle Overhauling
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Dismantling and assembly of Xenon axle shaft
bearing
Follow the Steps
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Unscrew nuts at brake anchor plate and remove the axle shaft
Remove the bearing cup using Puller slide hammer (part no 2658 5890 3507)
Remove snap ring near retainer ring
Remove retainer ring from axle shaft by drilling in it a 6.5 mm diameter hole till 5 mm depth
Use chisel to break the ring. Fit new ring while assembling
Use puller (part no 2698 5890 3521) to pull out inner race of axle shaft bearing. (Use same puller to press in the bearing)
Use workshop press to install the retainer ring. To confirm its seating, use filler gauge 0.038 mm which should not enter around diameter.

Dismantling and assembly of Xenon New HD axle
shaft
7/27/2022 TML 67
Shaft Holding Spanner
Shaft nut torque socket
266358903502
Spanner
250658900103
HUB BRG REMOVAL & PRESSING
TOOL 266358903501
Axle shaft hub brg. removal tool
266358903503
• Removal of Axle shaft Bearing
• Straighten the bent lock washer
into the nut
• Install locknut removal tool on
lock nut with socket and loosen
the nut. (Torque 45 Kgm)
• The Bearing should be replaced
with shaft
• LH shaft is having LH treads and
RH shaft is having RH threads for
lock washer.
• LH shaft is having groove on spigot
on shaft as shown in fig.
• Similar marking is made on
threaded nut.
• For removing of bearing holder
from shaft, install the puller on
shaft.
• Tight the 4 nuts and by rotating
handle of bearing puller remove
the bearing assy. from shaft.
• To remove the bearing from bearing
holder, put the bearing holder on
bottom locator.
• Install the drift and take out the
bearing using press.
• Note: Do not use the bearing again if
the grease is slipped out from
bearing.
• The bearing is sealed and no
lubrication is required.

Spicer Axle – Limited Slip Differential
 A limited slip differential (LSD) or anti-spin is a type of traction aiding device that uses a
mechanical system that activates under centrifugal force to positively lock the left and right
spider gears together when one wheel spins a certain amount faster than the other. The LSD
performs like an open differential under “normal” conditions, and automatically transfers
torque to the wheel with better traction when conditions demand.
 This system is similar to conventional differential, except that part of torque from ring gear is
transmitted through clutch packs between side gears and differential case. In case of wheel
slippage clutch pack opposite to slipping side, is activated by separating forces between
pinion mate and corresponding side gear. This increases torque delivered to non-slipping
wheel and vehicle begins to move.
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Note: LSD feature gets
activated & deactivated
automatically. No driver
intervention is required.

Removal of LSD Differential Assembly
Follow the Steps
7/27/2022 TML 69
Remove the differential cover plate by unscrewing cover plate screws
Remove the differential bearing caps. While assembling, ensure that the mating letters stamped on carrier and housing
are matched
Mount spreader (part no 2698 5890 3517) to the housing to spread the housing
Use dial gauge to ensure that the carrier is not spread more than 0.58 mm
Pry out differential case from carrier

Overhauling of Limited Slip Differential
Follow the Steps
7/27/2022 TML 70
Remove differential cross shaft by removing locking pin
Install adapter plate of track lock tool 2699 5890 3501 in bottom side gear
Install threaded adapter of track lock tool into top side gear
Screw in threaded adapter till it Is centered into adapter plate by using small screw driver to prevent adapter from turning
Torque driving bar of track lock tool to collapse Belleville plates
Remove pinion mate spherical washers
Loosen driving bar to relieve tension on belliville plates
Remove pinion mate gears by suitably rotating pinion mate gears
Remove tools & side gears with clutch pack

Pinion Depth Adjustment (Alternate Method)
1. Remove the Oil seal from top with tool.
2. Take out the pinion bearings.
3. Remove bearing cup.
4. Place master block and measure height.
5. Select the shim as per table and mark on
pinion.
6. Install bearing cone, bearings with new
collapsible spacer and new seal.
7. Collapsible spacer creates pre load on
bearings after torque the nut.
7/27/2022 TML 71
Pinion Height
Shim Selection
Pinion Bearing
Cup Removal
Pinion Oil Seal
Removing

Crown Wheel Pinion Backlash Adjustment of LSD
7/27/2022 TML 72
• Differential casing without ring
gear.
• Side play of differential case
without ring gear = A
• Differential casing with ring gear.
• Side play of differential case with
ring gear = B.
• Put shims towards the
backside of ring gear = B mm
to B-0.125 mm.
• Put shims towards the teeth
side of ring gear = A-B+0.2
mm.
Backlash = 0.13 mm to 0.2 mm (maximum variation at 3 points = 0.08 mm)

Spicer – Backlash Adjustment
Backlash Adjustment
 Total play observed (Without crown wheel) = A
 Left hand play (With crown wheel) = B
 Right hand play = (A-B) = C
– Suppose A = 1.75 (0.070”)
– B = 1.01 (0.040”)
– C = 1.75 – 1.01 = 0.74 (0.030”)
Backlash Calculations:
 Ring Gear Side: Assemble shim pack to measurement B – 0.125 or B-0.005”
 Opposite Side of Ring Gear
 Assemble shim pack to measurement C. Add 0.20 mm or C+ 0.008” for differential bearing
preload & backlash.
7/27/2022 TML 73

Chart for New pinion Replacement- Spicer LSD
7/27/2022 TML 74
Old pinion
marking
New pinion marking
-4 -3 -2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

 Removal & Dismantling of Crown Wheel & Tail
Pinion Assembly
 Inspection of Crown Wheel & Pinion Assembly
Removal, Dismantle, Inspection & Re-fitment of Rear
Axle Carrier Assembly – 407/709 Type
7/27/2022 TML 75
Removal, Dismantle,
Inspection & Re-fitment
of Rear Axle Carrier
Assembly – 407/709
Type

 Assembly of Tail Pinion in the Housing
 Assembly of Crown Wheel
 Installation of Crown Wheel Assembly in to
Housing
 SST Involved
Assembly & Installation of Crown Wheel & Pinion
Assembly – 407/709 Type
7/27/2022 TML 76
Assembly & Installation
of Crown Wheel &
Pinion Assembly –
407/709 Type

Rear Axle System – 407 Type –Technical Specification
7/27/2022 TML 77
Sl. No Description Value in mm
1 Rear Axle housing max. permissible bend 2
2 End play of axle shaft gears 0.025 to 0.10
3 Brass thrust washer (for axle shaft gears) available in thickness 1.95 to 2.25 in steps of 0.05
4 Maximum permissible lateral runout of crown wheel mounting face on diff case 0.06
5 Backlash between crown wheel & tail pinion 0.25 to 0.33
6 Pre-load on tail pinion bearings toe give a friction movement 14 to 30 cm.kg
7 Thickness of split ring for tail pinion 7.6 to 8.2 in step of 0.02 and 9.26
8 Permissible variation in tail pinion depth -0.1
9 Maximum permissible runout of axle shaft near neck and centre of shaft 0.7
10 Clearance between thrust pad and crown wheel 0.25
11 Hub Play 0.04 to 0.1
12 Hub Inner bearing mounting ore dia 124.952 / 124.912
13 Hub outer bearing mounting bore dia 109.959 /109.924
14 Axle beam inner bearing seat dia 69.980 / 69.967
15 Axle beam outer bearing seat dia 59.980 / 59.967
16 Pre-load on differential side bearings 0.02 to 0.04

Maintenance Schedule - Rear Axle – 407 Type
 Oil & Lubricants:
 Maintenance Schedule:
7/27/2022 TML 78
Filling Capacity 1.5 Litres.
Oil Used 85 W 140 / API GL 5, Anglamol 99; 6.5 % by weight
Brand Telco spirol Castrol Hypoid
HD85W140 B 85W140
Activity Frequency in Kilometres
Check oil level in rear axle, top up if necessary 5000
Check rear hub bearing play 5000
Change oil in RA for first 10,000 kms and every 40000
Change grease in rear hub adjust bearing play replace
damaged worn out parts
20000

Rear Axles – LCV/RA108/LSD
Important Settings & Adjustment
7/27/2022 TML 79

Major Adjustments (Pinion Preload Setting)
7/27/2022 TML 80
Tail Pinion Assy. Torque the lock nut Measure the split spacer
Assemble the pinion with bearings and
press coupling flange
Hold coupling flange in vice and torque
the lock nut to spec torque
Measure the split spacers and select the
spacer
Take two equal spacers and feel the
movement between two bearings. The
spacers are available in different sizes
Split the spacer and insert from both
sides. To increase the load take higher side
spacer and lower size to decrease load
Preload to be adjusted using spacer
rings & frictional torque to be measured
using special tool.

Important Settings / Adjustments Pinion Depth
7/27/2022 TML 81
Check the marked pinion depth on crown
wheel. Ensure same no. on crown wheel
and pinion.
It must be changed in pair.
Measure the pinion depth with the help of
special tool with master piece. Say it is 55.62
Measure depth as shown on pinion face.
Say it is 54.09 the difference between tool
master piece and pinion depth. I.e. 55.62 –
54.09 = 0.53mm.
As Marked depth is 54.09 then set shim of
0.53mm.
To increase the depth, increase shim size
and to decrease depth, reduce shim size.
Use stepped jaws to hold pinion flange, it will
not allow split spacers to be out during
hammering.
Tight the pinion with special tool and torque
multiplier to required torque. Tight the
pinion with special tool and torque
multiplier to required torque.

Important Settings / Adjustments Backlash
7/27/2022 TML 82
Step - 7 Step - 8
• Ensure the LHS and RHS side differential bearings and caps are
fitted.
• Set the crown wheel and tight the plumber block bolt with 3 Kgm
torque. Set the crown wheel with 0.5 to 1 mm.
• Ensure threaded ring movement after fitment.
• Tight both the threaded ring at the same time revolve the assy.
• Insure the backlash should .5 to 1 mm
Step - 9 Step - 10
• Tighten the left threaded ring till the backlash should be 0.15
mm. Tighten the LH side bolt half of torque.
• Tight the RHS threaded ring to required backlash.
• Tight the both the side differential bolts to full torque and rotate
crown wheel and check the back lash at 4 places.

Important Settings / Adjustments
7/27/2022 TML 83
Differential gear backlash Crown Wheel run out checking Thrust pad screw setting
Select specified equal size of washers
and place at both ends of sun gear.
Tight the differential and cover with
torque. Measure gear back lash with
filler. If not ok, open and change the
spacer width
Mount dial gauge with the help of
holder on housing to check lateral run
out of crown.
Max. permissible : 0.06 mm
Tighten the screw in the housing till the
thrust washer rests on the machined
surface of the of the crown wheel. Then
turn the screw back by 1/6th of a turn &
lock the check nut. Clearance of 0.25
mm between the face of the thrust pad

Adjustments- RA1068 Pinion Bearing Preload
7/27/2022 TML 84
Take out the cover of pinion bearing housing
with tool
Remove both the Pinion Bearing Check the size of shims and fit in between
bearing spacer
Step - 4 Step - 5
Put the pinion hsg. along with the bearing
outer races on the pinion with inner bearing
inner race
Check the preload on the bearings
After checking the preload, after the spacer ring in order to get a bearing preload of 30-60kg-
cm. (for more bearing preload select shim of lesser thickness)

Adjustments Pinion Depth For RA 1068)
7/27/2022 TML 85
Step - 1 Step - 2
• Check the marked pinion depth on crown wheel. Ensure same no. on
crown wheel and pinion.
• It must be changed in pair.
• Tail Pinion Depth
Measurement Tool.
• Measure the pinion depth with
the help of special tool and
calculate the difference
between tool master piece and
pinion depth
• Select correct size of shim,
marked depth is 89.00, actual
depth is 88.1.
• Add 0.9mm shim to achieve the
depth,
• Fit the pinion housing on
carrier housing with shims and
tighten bolts with torque.

Adjustments Backlash For RA 1068
7/27/2022 TML 86
• Set the crown wheel in housing
• Set the crown wheel in housing
with LHS and RHS bearings.
• Torque the Plummer block bolts
and ensure free movement of
threaded ring.
• Check back lash at 4 places
• Torque the LHS bolt with half
torque value and set the Back
lash to 0.07 mm. Torque both
bolts and move crown wheel
till desired back lash value.

Ring Gear & Pinion Tooth Contact Pattern
 Paint ring Gear teeth with a marking
compound on both the drive & coast side
 Rotate the Ring Gear one complete
rotation in both direction while applying
load with a large screw driver or similar
tool between the carrier casting and
differential casing
 Decreasing the backlash moves the ring
gear closer to the pinion
 Increasing the backlash moves the ring
gear away from the pinion
7/27/2022 TML 87

Ring Gear & Pinion Tooth Contact Pattern
Pattern- A:
 Normal or desirable pattern. The drive pattern
should be centred on the tooth. The coast
pattern should be centred on tooth, but may be
slightly towards toe. There should be some
clearance between pattern & the top of the
tooth.
Pattern-B:
 Backlash Correct – Thinner pinion shim required
Pattern -C:
 Backlash Correct- Thicker pinion shim required
Pattern -D:
 Pinion position shim correct. Decrease Backlash
Pattern-E:
 Pinion Position shim correct. Increase Backlash
7/27/2022 TML 88

Rear Hub Play Adjustments
Hub Play with spacer and shim :
 Measure hub play after fixing the magnetic
stand of the dial gauge on suitable
mounting surface. Measure the hub play
 For example, Let the shim pack is of 2.5
mm, let the initial hub play is 0.5 mm. The
required hub play will be 0.04mm. To get
correct shim size for hub play of 0.04 mm
the new shim pack will be (2.50 - 0.50 +
0.04) = 2.04 mm.
 The recommended hub play is between
0.02 to 0.06 mm.
7/27/2022 TML 89

Hub Play Setting – RA 1068
7/27/2022 TML 90
Using torque, loose the lock nut. Using puller take out the hub.
Measure shim of 2.5mm & set the
hub without grease, measure the
hub play by moving hub. Note and
take out hub.
Calculate new shims pack to achieve
specified hub play and re-install hub
with new shims and filling specific
qty of grease. Torque the lock nut.
Hub play to be measured &
adjusted using dial gauge with
special tool or magnetic stand and
dial gauge.

Important Setting / Adjustment Values
7/27/2022 TML 91
Settings 1109 / 1112 407 Ultra RA 109 RR
Back lash between Crown
Wheel & Tail Pinion
0.20 - 0.26 mm 0.20 - 0.26 mm 0.24 - 0.30 mm 0.28 - 0.34 mm
Crown Wheel Run Out 0.06 mm 0.06 mm 0.06 mm 0.06 mm
Hub Play 0.02 - 0.04 mm 0.01 - 0.03 mm 0.04 - 0.12 mm 0.04 - 0.12 mm
Preload on Tail Pinion bearing 30 - 60 cm-kg 5 - 20 cm-kg 30 - 60 kg-cm 15 - 36 cm-kg
Tail Pinion depth value etched on crown wheel

Dos & Don'ts for Rear Axles
Do's
 Select shims for hub bearing spacer
without fixing oil seal and without packing
grease.
 Ensure free play for the hub bearings as
per specification, preferably on the lower
range of the specification.
 Always use dial gauge for setting hub free
play as feel method will always mislead.
 Ensure preloading of differential side
bearings while adjusting crown wheel and
pinion backlash.
Don'ts
 Do not wash the bearings, differential,
crown-wheel and pinion etc. in water or
kerosene.
 Do not punch the bearing seat to increase
the interference of bearing inner race on
spindle.
 Do not preload the hub bearings.
 Do not over-fill grease in the hub. Over-
filling of grease will cause excessive
churning of grease thereby excessive heat
generation and grease melting.
 Axle tubes should not be cambered. It will
affect the tyres life.
7/27/2022 TML 92

All The Best!
7/27/2022 TML 93

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