The document provides instructions for dismantling and reassembling wheel loader axles. It describes how to: - Remove the wheels and propeller shaft and lift the axle out of position. - Disconnect hydraulic motors, brake lines, and lubrication lines before extracting the rear axle. - Reassemble by reversing the removal process and refilling lubricants. - Dismantle wheel hub assemblies by removing bearings, seals, and gears. - Take apart front and rear axle drive assemblies by dismantling differentials, brakes, and gearing components. - Reassemble components by pressing in new seals and bearings, replacing worn parts, and adjusting preloads.

1. Wheel Loader
TECHNICAL HANDBOOK
Publication no. 604.06.995.02 issue 07/02
FIAT KOBELCO

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Dismantling and Reassembling the Axles
Dismantling
• Slacken wheel nuts (141, Fig. 1 + 2).
• Lift loader and support safely. Drop bucket onto
ground.
• Take off wheels.
• Remove propeller shaft.
• Move fork-lift truck under axle from the side, lift
and jack up axle.
Front Axle:
• Remove two screw clips (142 - 144, Fig. 1).
Rear Axle:
• Disconnect hydraulic motor (201, Fig. 2) flange
and suspend.
• Loosen parking brake bowden cable.
• Unscrew service brake pipings (202) and close
openings.
• Unscrew self-aligning bearing lubrication piping
(203, 204).
• Extract pin (145).
• Lower fork-lift truck and pull out axle.
Reassembling
• Reassemble the axles in the reverse order.
• Successively fill oil into wheel hubs, transfer
box (rear axle only) and axle drive assembly.
Refer to Operating Instructions.
• Vent brake assembly.
• After adjusting parking brake, tighten brake le-
ver screws (93).
Tightening torque MA = 26 Nm (19 lbft).
• Lubricate self-aligning bearing (rear axle only).

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Fig. 1

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Fig. 2

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Dismantling the Front Axle
Wheel Hub Assembly
If the repair is restricted to the hub and the
planetary gear set dismantling and reassembling
may also be done on the wheel-mounted loader
with the axle in horizontal position.
• Axle Mounted:
- Remove wheel, bleed oil from wheel hub and
drop oil level in axle.
• Axle Removed:
- Bleed oil from hubs and axle.
- Mark axle housing (27, Fig. 1) and both axle
tubes (101).
- Slacken hex screws (106).
- Take off axle tubes (101) incl. wheel hubs
and place in vertical position with hub on top.
• Slacken two hex screws (111), lift off planetary
carrier (127) and remove O-ring (126).
• Unlock snap rings (122) and pull off spur gears
(121) incl. bearing (123) with suitable extractor.
• Remove thrust washer (125).
• Extract pinion shaft (124).
Fig. 1

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• Slacken hex screws (120), loosen ring gear
(119) and carrier (118) by mounting lever, see
Fig. 2, and lift off.
Fig. 2
• Unlock snap ring (117), push carrier (118) out
of ring gear (119).
• Remove spacing washers (114 - 116).
• Close hole in axle tube (101) with suitable
washer and pull off hub (113) with suitable
extractor.
Recommended: Extract hub (113) with conven-
tional hydraulic press (Lukas). Refer to Fig. 3.
Fig. 3
• Remove tapered roller bearing (110), lift shaft
ring (109) and remove second tapered roller
bearing (110) from hub (113).
• Drive outer rings of bearings (110) out of hub,
if bearings are to be replaced.
• Unscrew vent plug (102) and clean.

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Axle Drive Assembly
• Dismantle complete axle. Refer to "Dismantling
and Reassembling the Axles".
• Bleed oil from wheel hubs and axle
• Mark axle housing (27, Fig. 4) and both axle
tubes (101). Place axle in vertical position so
that - seen in driving direction - the left-hand
axle half is on top. At this position, ring gear
(21) is on top. Refer to "Front Axle Drawing".
Fix lower axle tube. For holding fixture, refer to
"List of Special Tools" chapter.
• Slacken hex screws (106) and lift off axle tube
(101). Hub and planetary gear set remain
closed.
• Remove O-ring (107).
• Extract drive shaft (108).
• Lift out complete differential assembly with de-
vice S28.
• Pull drive shaft (108)out of lower axle tube.
• Arrest flange (50) with crank S27, slacken col-
lar unit (51) and pull off flange (50).
• Lift shaft ring (48).
• Drive pinion shaft (21) into axle housing (27),
catch released tapered roller bearing.
• Extract spacing washers (44 - 46), bush (40)
and tapered roller bearing (36) from pinion
shaft.
• Drive outer rings of tapered roller bearings (36
+ 47) out of axle housing if bearings are to be
replaced. Remove spacing washers (37 - 39).
Fig. 4

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Differential Assembly
• Mark both halves of differential housing (20,
Fig. 6).
• Slacken fillister-head screws (22) and remove
ring gear (21).
• Separate differential housing (20), remove pin
(12) with bevel gears (13) and washers (14).
• Remove bevel gears (15) and disks (16 - 18)
from casings (20).
• Drive both tapered roller bearings (23) off dif-
ferential housing (20). Put suitable punch on
inner bearing rings from inside through oil
holes. Refer to Fig. 5.
• Pull rings of tapered roller bearings (23) out of
axle tubes if bearings are to be replaced. Re-
move spacing washers (24 - 26).
Fig. 5
Fig. 6

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Dismantling the Rear Axle
Fig. 1
Wheel Hub Assembly
Refer to Chapter "Wheel Hub Assembly". Only
the tube shape differs from the front axle (101,
Fig. 1).
Brake Assembly
• Remove complete rear axle. Refer to Chapter
"Dismantling and Reassembling the Axles".
• Bleed oil from wheel hubs, axle tubes and axle
drive.
• Mark axle tubes (101, Fig. 2), brakes (72 + 73)
and axle housing (27).
• Place axle in vertical position and fix at lower
tube. If one brake is to be repaired only the
latter must be on top.
• Slacken hex screws (106, Fig. 1) and lift off
axle tube (101). Hub and planetary gear set
remain closed.
• Remove O-ring (107).
• Extract drive shaft (108).
• Remove disks (83 + 84, Fig. 2) from brake
carrier.

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• Lift off brake carrier (72/73) and remove O-ring
(74).
• Remove second axle half from mount, turn and
put on axle housing (27). Dismantle axle tube
(101) and brake carrier (72/73) as described
above.
• Bleed brakes completely (hydraulic oil).
• Remove fillister-head screws (81), take out
springs (80) and bushes (79).
• Remove back-up ring (77).
• Screw fillister-head screws (81) into brake pis-
tons (75) and pull out latter by hand.
Remove packing rings (76).
• Dismantle lever (90/91), push shaft (85) into
brake carrier and drive out needle sleeves
(87 + 88).
• Check brake piston (75) and cylinder for marks
and wear.
• Check and measure brake disks (83 + 84).
The disks will have to be replaced if the inner
ones (84) have worn down to their minimum
thickness of 4.5 mm. The wear of the lining
must be equal on either side, with a minimum
groove depth of 0.2 mm/side.
Thickness (mm)
Brake disk NEW MIN
Inner disk (84) 4,9-0,1
4,5
Outer disk (83) 3_
+0,1
The outer disks (83) must be replaced if the
surface (steel) is rough or scratched. All inner
disks (84) bzw.
Replace disks (83 + 84) only in sets.
Fig. 2

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Axle Drive Assembly
• Remove complete rear axle. Refer to Chapter
"Dismantling and Reassembling the Axles".
• Bleed oil from wheel hubs and axle. Mark axle
tubes (101, Fig. 2), brake carrier (72/73) and
axle housing (27).
• Place axle in vertical position so that - seen in
driving direction - the right-hand axle half is on
top. At this position, ring gear (21) is on top.
Refer to Chapter "Rear Axle Drawing". Fix low-
er axle tube. For holding fixture, refer to Chap-
ter "List of Special Tools" chapter.
• Lift off hex screws (106, Fig. 1) and axle tube
(101). Hub and planetary gear set remain
closed.
• Remove O-ring (107).
• Extraxt drive shaft (108).
• Lift off complete brake assembly (72, Fig. 3)
and remove O-ring (74).
• Lift out spacing washers (24 - 26) and com-
plete differential assembly with device S28.
• Extract drive shaft (108) from lower axle tube.
• Arrest flange (50, Fig. 4) with crank S27, slack-
en collar unit (51) and pull off flange (50).
Fig. 3

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• Slacken hex screws (55). Take off transfer box
(53) and remove O-ring (54).
• Drive shaft ring (48) out of housing.
• Pull off spur gear (52).
• Push pinion shaft (21) into axle housing (27),
remove spacing washers (44 - 46), extract
bush (40) and tapered roller bearing (36) from
shaft.
• Extract tapered roller bearing (47) from spur
gear (52).
• Drive outer rings of tapered roller bearings (36
+ 47) out of axle housing if bearings are to be
replaced. Remove spacing washers (37 + 39).
Fig. 4

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Differential Assembly
Refer to Chapter "Differential Assembly". Instead
of the self-locking differential disks, one bearing
ring (19, Fig. 5) is installed on each side in the
rear axle differential.
Fig. 5

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Assembling the Front Axle
Wheel Hub Assembly
The following illustrations show axle tube (101) in vertical position, i. e. the complete axle is removed.
Fig. 1
Insert outer ring of tapered roller bearing (110)
into hub (113).
Fig. 2
Apply punch (S11).
Fig. 3
Force bearing outer ring into hub by hydraulic
press.

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Fig. 4
Insert tapered roller bearing (110).
Fig. 5
Apply shaft ring (109) so that outer flange faces
top. Refer to Fig. 6.
Fig. 6
Apply sealing compound to surface (A) of shaft
ring (109) and hub (113).
Fig. 7
Press in shaft ring (109). Pressing depth is limited
by flange.

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Fig. 8
Turn over hub.
Insert outer ring of tapered roller bearing (110).
Fig. 9
Press in bearing ring.
Fig. 10
Place axle tube (101) in vertical position.
Apply grease to hub carrier.
Fig. 11
Put hub on axle tube.

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Fig. 12
Screw two pins of mounting fixture (S13) into axle
tube (101).
Fig. 13
Apply mounting fixture (S13) with screwed-in cyl-
inder for conventional hydraulic presses (Lukas).
Fully press hub onto axle tube.
Fig. 14
Insert tapered roller bearing (110).
Apply new die of mounting fixture (S13) to bear-
ing ring.
Fig. 15
Increase pressure of hydraulic press to approx.
200 bar (2903 psi). Give hub a few taps with
plastic mallet for settling.
Reduce pressure to 50 bar (726 psi) and turn hub
(113) by hand. This value yields the axial
prestress of 0.05 - 0.15 mm required for new
tapered roller bearings (110).

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Fig. 16
Measure distance between die of mounting fixture
(S13) and surface (A) on inner ring of tapered
roller bearing (110) with depth gauge.
(Digital meter to be set to "0".)
Fig. 17
Subsequently, measure face (B) of axle tube
(101).
Difference between A and B = X.
The dismension may be in the positive or nega-
tive range.
Example 1 : X = 0.22 mm.
or
Example 2 : X = - 0.12 mm.
Record measured value.
Fig. 18
Insert ring gear carrier (118) into ring gear (119).
Fig. 19
Lock in snap ring (117).

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Determine difference between recess (C) an an-
nular surface (D) on ring gear carrier (118):
Fig. 20
Measure recess (C).
(Digital meter to be set to "0".)
Fig. 21
Measure annular surface (D) of ring gear carrier.
Repeat both measurement with a 180˚ offset.
Average of between C and D = Y.
Example 1 : Y = 0.50 mm.
or
Example 2 : Y = 0.48 mm.
Record measured value.

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Figs. 22 and 23
Calculating Spacing Washers (114 - 116)
Example 1:
X 0.22 mm
Y + 0.50 mm
0.72 mm
Pre-tension + 0.03 mm
0.75 mm
Rounded up 0.80 mm
1 no. of spacing washer 0.50 mm
1 no. of spacing washer 0.30 mm
Example 2:
X - 0.12 mm
Y + 0.48 mm
0.36 mm
Pre-tension + 0.03 mm
0.39 mm
Rounded up 0.40 mm
1 no. of spacing washer 0.30 mm
1 no. of spacing washer 0.10 mm
Always round up the value calculated.
Spacing washers (114 - 116) 0.1 - 0.3 - 0.5 mm
thick.
If possible, keep the number of spacing washers
small.
Fig. 24
Moisten eight tapped holes of axle tube (101)
with LOCTITE 243.

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Fig. 25
Put on spacing washer(s) (114 - 116) determined.
Fig. 26
Put on ring gear carrier (118) with ring gear
(119).
Fig. 27
Drive ring gear carrier fully down on bearing sur-
face with punch (S14).
Fig. 28
Crosswise tighten hex screws (120).
Tightening torque MA = 120 Nm (89 lbft).

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Fig. 29
Put thrust washer (125) with LOCTITE 243 in
planetary carrier (127) and drive in with suitable
punch.
Fig. 30
Put up spur gears (121) with their big bevels
down.
Put on spur gear new roller bearing (123) in PVC
sleeve with radius in inner ring down and centre
exactly.
Fig. 31
Firmly press PVC sleeve onto spur gear.
Quickly push roller bearing (123) into spur gear
with suitable punch until snap ring (123.1) locks
into spur gear groove from bearing middle.
Fig. 32
Fitting position.

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Fig. 33
Warm up in oven spur gears (121) with bearing
for approx. 30 minutes at maximum of 100˚C
(212˚F).
Put warm spur gear on planetary carrier pivot
with big bevel down.
Fig. 34
Fully drive in bearing with punch (S15).
Fig. 35
Lock in snap rings (122).
Fig. 36
Put on O-ring (126).