Order no.

: 5871 216 002

ZF – PORTAL AXLE AVN-132

Version: Wheel head with compact bearing

ZF Passau GmbH
Donaustr. 25 - 71
D-94034 Passau
 REPAIR MANUAL
ZF – PORTAL AXLE AVN-132
Version: Wheel head with compact bearing

Note:
Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current
ZF production unit.
This documentation has been developed for specialized staff trained by ZF Passau for repair work to be
made on ZF-units.
Continuous technical upgrading of the ZF units and extensions concerning design options may require
differing workings steps as well as deviating setting and test data.

This disassembly and reassembly manual is based on the design level of a ZF production unit at the time of
issue of the manual.

ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a
successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise
which edition is the latest one.

When carrying out maintenance works the specifications made in Lubrication and Maintenance
Instructions
(ZF-order no.: 5871 216 902) and ZF-List of Lubricants TE-ML 12, must be observed!
The List of Lubricants is being continuously updated and can be obtained or viewed as follows:
- In all ZF-plants
- In all ZF-service organizations
- Internet [Link] Service / Techn. Information
----------------------------------------------------------------------------------------------------------------------------------

When carrying out service and maintenance work on the brake, the specifications of the
corresponding brake manufacturer and of the vehicle manufacturer must be observed.

CAUTION:
Observe the vehicle manufacturer’s instructions and specifications for the installation and
commissioning of the unit!

ZF Passau GmbH
Donaustr. 25 - 71
94034 Passau
Division: ASDM
Copyright ZF Passau GmbH! Complete or partial reproduction is not permitted!
Design level : 2007/12
TABLE OF CONTENTS Chapter/Page

Preface 0/1

General working instructions 0/2

General and important information on labor safety 0/3

Conversion table 0/4

Denomination of standard dimensions 0/5

Tightening torques for plugs 0/6

TOOLS

SPECIAL TOOLS WS/1 ... 3

COMMERCIAL TOOLS WH/1 ... 5

1. DISASSEMBLY OUTPUT and HUB CARRIER 1/2 … 7

2. REASSEMBLY OUTPUT and HUB CARRIER 2/1 … 8

3. AXLE HOUSING/ PORTAL HOUSING 3/1 … 3

3.1 One piece standard version 3/1

3.2 One piece with bolted bracket 3/1

3.3 Multi-part with fixing plate (version 1) 3/2

3.4 Multi-part with fixing plate (version 2) 3/2

3.5 Multi-part – input axle housing 3/3

4. COMPONENTS 4/1 … 4

4.1 Overview 4/1

4.2 Description of components 4/2 … 4

4.3 Axle version with stabilizer link (track guidance system) 4/4
 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

PREFACE

This documentation has been developed for specialized staff trained by ZF Passau for repair and
maintenance work to be made on ZF units.

This documentation describes a ZF series product with a design level valid at the date of edition.

Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and differing setting and test data.

We would therefore recommend you to entrust masters and servicemen with the work on your ZF product
whose practical and theoretical training is constantly updated in our training school.

The Service Stations established by ZF Friedrichshafen all over the world offer you:

1. Permanently trained staff

2. Specified equipment, e.g. special tools

3. State-of-the-art genuine ZF spare parts

All work is done there with utmost care and reliability.

In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the terms
of the currently applicable contractual conditions.

Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred shall be excluded from this contractual liability.

This shall also be applicable if other than genuine ZF spare parts are used.

This manual is based on the state-of the-art at the time of printing.

It was prepared with utmost care in order to avoid errors.

However, we shall not be liable for any possible errors in figures or descriptions

ZF Passau GmbH

Service Department

5871 216 002 0/1

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

GENERAL

The Service Manual covers all work required for disassembly and the relating reassembly.

When repairing the unit, ensure utmost cleanliness and that the work is done in a professional manner.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids
and housing parts which were installed with seals by slight blows with a plastic hammer. Use suitable
pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing rings and
similar.

Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids from
residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and end
covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts must be
replaced, with an expert assessing whether parts subject to normal wear during operation, such as bearings,
thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings with
worn or broken sealing lip must also be renewed. In particular, ensure that no chips or other foreign bodies
remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation:

NOTE: Only a heating furnace (oil bath) or an electric drier is permitted to be used for heating up parts
such as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a perfect contact.

CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated in the manual.
Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.

When fitting snap rings and retaining rings, pay attention to an exact contact in the grooves!
Never wash disks having organic friction linings (e.g. paper disks ) - adverse effect on lining adhesion.
Only dry cleaning is permitted (leather cloth).

DANGER:
When using detergents, observe the manufacturer’s instructions regarding their handling.

5871 216 002 0/2

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Structure of the Service Manual

The structure of this repair manual reflects the sequence of work steps for completely dismantling the
removed unit.

Special tools required for carrying out the repair work are listed in the current text as well as in
chapters “WS” (special tools) and “WH” (commercial tools).

Important information on labor safety

As a basic principle, the party repairing ZF units shall be fully responsible for labor safety.
The observance of all valid safety regulations and legal requirements is a prerequisite for avoiding
any damage to persons and products during maintenance and repair work.
Repair workshops must familiarize themselves with these regulations prior to starting any work.

A suitably trained and skilled staff is required for a proper repair of these ZF products.

The repair workshop shall be responsible for the training.

The following safety references are used in this manual:

This symbol serves as a reference to special working procedures,
) CAUTION methods, information, use of auxiliaries etc... indicated in this
repair manual.

This symbol identifies situations in which lacking care may lead to

DANGER personal injury or damage to the product.

NOTE: Thoroughly study this manual before starting any tests or repair work.

NOTE: Figures, drawings and parts in this manual do not always represent the original; they show
the working procedure.

Since the figures, drawings and parts are not shown to scale, do not draw any conclusions on
size and weight (not even within one and the same illustration).
Carry out work according to the legend.

NOTE: After repair work and tests, the expert staff must verify that the product is perfectly
functioning again.

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION

25.40 mm = 1 in ( inch)

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

9,81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)

1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )

1 kg / cm = 5.560 lb / in ( pound per inch )

1 bar ( 1.02 kp/cm2 ) = 14.5 psi (pound force per square inch lbf/in2 )

=
0.070 bar ( 0.071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0,264 Gallon ( Imp. )
=
4.456 Liter 1 Gallon ( Imp. )
=
1 Liter 0,220 Gallon ( US )
=
3.785 Liter 1 Gallon ( US )
=
1609.344 m 1 Mile ( land mile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273.15 Kelvin

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES

Hinweis : längenbezogene Maße in kg/m; flächenbezogene Maße in t/m2

Note : linear density in kg/m; areal density in t/m2

Nota : Densité linéaire en kg/m; Densité superficielle en t/m2

Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

Unit Formel Sign New Old Conversion Note
Uniteo Symbole Nouveau Vieu Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9.81 N
Force
Force
Arbeit A J (Joule) kpm 0.102kpm = 1J = 1Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW
Power 1 KW = 1.36 PS
Puissance
Drehmoment T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) =
Torque F (N) . r (m)
Couple
Kraftmoment M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) =
Moment (Force) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1.02 atü = 1.02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148

Friction coefficient: µ tot.= 0.12 for screws and nuts without rework, as well as phosphated nuts!
Tighten manually
Unless otherwise specified, the tightening torques can be taken from the following chart:

Metric ISO standard thread DIN 13, page 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO standard thread DIN 13, page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300

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 Corporate Division
Repair Manual Off-Road Driveline Technology and
Axle Systems

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

ZF-PORTAL AXLE
AVN-132
4472 036 337
Figure Designation Qty. Chapter/
Cons. Order no. Figure
No.

Assembly truck 1/1

5870 350 105 1

1

Supports 1/1

5870 350 077 (1 set = 2 pcs..) 1

2

Clamping bracket 1/1

5870 350 075 (1 set = 2 pcs..) 1

3

Slotted nut wrench 1/8

2/22
5870 401 146 1 2/24
4

Lifting bracket 1/9

2/21
5870 281 043 1
5

5871 216 002 WS/1

 Corporate Division
Repair Manual Off-Road Driveline Technology and
Axle Systems

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

ZF-PORTAL AXLE
AVN-132
4472 036 337
Figure Designation Qty. Chapter/
Cons. Order no. Figure
No.

Eyebolt set 1/19

2/4
5870 204 002 1
6

Eye nut 1/19

2/4
5870 281 054 1
7

Pressing fixture 2/1

5870 506 162 1

8

Wheel bolt puller – Basic device 2/8

5870 610 010 1

9

Insert M22x1.5 2/8

5870 610 002 1

10

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 Corporate Division
Repair Manual Off-Road Driveline Technology and
Axle Systems

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

ZF-PORTAL AXLE
AVN-132
4472 036 337
Figure Designation Qty. Chapter/
Cons. Order no. Figure
No.

Driver tool 2/9

5870 050 007 1

11

Handle 2/9

5870 260 004 1

12

Arbor 2/11

5870 345 121 1

13

Driver tool 2/15

2/16
5870 051 053 1
14

Inner installer 2/19

5870 651 085 1

15

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 Corporate Division
Repair Manual Off-Road Driveline Technology and
Axle Systems

SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

ZF-PORTAL AXLE
AVN-132
4472 036 337
Figure Designation Qty. Chapter/
Cons. Order no. Figure
No.

Adjusting screw 4/2

M20x1.5 ( 1 set = 2 pcs.)
1
16 5870 204 044

Adjusting screw
M18x1.5 ( 1 set = 2 pcs.) 4/5

5870 204 029 1

17

5871 216 002 WS/4

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Magnetic stand

5870 200 055

1 1 Universal

Dial indicator

5870 200 057

2 1 Universal

Gauge blocks

5870 200 066 70 mm

3 1 Universal
5870 200 067 100 mm

Digital depth gauge

5870 200 072 200 mm

4 1 Universal
5870 200 114 300 mm

Digital caliper gauge

5870 200 109 150 mm

5 1 Universal

5871 216 002 WH/1

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Torque wrench

5870 203 030 0.6 -6.0 Nm

5870 203 031 1.0 – 12 Nm

5870 203 032 3.0 – 23 Nm

6 1 Universal
5870 203 033 5.0 – 45 Nm

5870 203 034 10 – 90 Nm

5870 203 039 80 – 400 Nm

5870 203 016 140 – 750 Nm

5870 203 011 750 - 2000 Nm

Hot air blower

5870 221 500 230 V

7 1 Universal
5870 221 501 115 V

Plastic hammer

5870 280 004 Ø 60 mm

8 1 Universal
Substitute nylon insert

5870 280 006

Lifting strap

5870 281 026

9 1 Universal

5871 216 002 WH/2

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Lifting chain

5870 281 047

10 1 Universal

Pry bar

5870 345 071

11 1 Universal

Striker

5870 650 004

12 1 Universal

Set of internal pliers

I1-I2-I3-I4

13 5870 900 013 1 Universal

Set of internal pliers

I11-I21-I31-I41 90°

14 5870 900 014 1 Universal

5871 216 002 WH/3

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Set of external pliers

A1-A2-A3-A4

15 5870 900 015 1 Universal

Set of external pliers

A01-A02-A03-A04 90°

16 5870 900 016 1 Universal

Two-armed puller

5870 970 001

Jaw width 80 mm
Throat depth 100 mm
5870 970 002
Jaw width 120 mm
Throat depth 125 mm
5870 970 003
Jaw width 170 mm
Throat depth 125 mm
5870 970 004
17 Jaw width 200 mm 1 Universal
Throat depth 175 mm
5870 970 006
Jaw width 350 mm
Throat depth 250 mm
5870 970 007
Jaw width 520 mm
Throat depth 300 - 500 mm
5870 970 026
Jaw width 250 mm
Throat depth 200 mm
5870 970 028
Jaw width 380 mm
Throat depth 200 mm

5871 216 002 WH/4

 Corporate Division
Repair Manual Off-Road Driveline Technology
and Axle Systems

COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY

Cons. Figure Designation Qty. Chapter/Fig .

No. Order no.

Three armed puller

5870 971 001

Jaw width 85 mm
Throat depth 65 mm
5870 971 002
Jaw width 130 mm
Throat depth 105 mm
5870 971 003
Jaw width 230 mm
18 Throat depth 150 mm 1 Universal
5870 971 004
Jaw width 295 mm
Throat depth 235 mm
5870 971 005
Jaw width 390 mm
Throat depth 270 mm
5870 971 006
Jaw width 640 mm
Throat depth 300 mm

5871 216 002 WH/5

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

ZF – PORTAL AXLE
AVN- 132

Fix ZF portal axle to the assembly truck.

(S) Assembly truck 5870 350 105

(S) Supports 5870 350 077
(S) Clamping bracket 5870 350 075

Figure 1

Separate brake from the axle (see Figures 2 to 5)

When working on the brake system, the instructions and

specifications of the respective brake manufacturer are
binding!
The relevant information is included in the repair and
maintenance instructions of the component manufacturer!
The latest updates of the individual instructions can be
ordered by the brake manufacturer or looked up at the
available internet site!
Brake manufacturer and brake type (see arrow) can be
taken from the identification plate of the brake caliper!
Figure 2 Figure 2 shows the position of the identification plate (see
arrow) with the example of a KNORR brake!

Loosen the spring accumulator.

Figure 3

Remove the protective cap and reset the adjuster

(in counterclockwise direction).

) Required only, if brake disk is severely worn!

) Snapping noises are normal!

Figure 4

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Loosen hexagon screws and separate brake caliper from the axle.

Figure 5

1. Disassembly output and hub carrier

Support hub and loosen hexagon screws.

Separate cover from the hub.

Figure 6

Unlock slotted nut.

Figure 7

Loosen outer slotted nut and remove the releasing locking plate.

Then loosen inner slotted nut.

(S) Slotted nut wrench 5870 401 146

Figure 8

5871 216 002 1/2

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Use lifting device (S) to separate hub/brake disk from the hub
carrier.

(S) Lifting bracket 5870 281 043

When removing the parts be careful not to damage the

thread on the hub carrier!

Figure 9

Fix hub/brake disk to the press.

Loosen the threaded connection and separate the hub from the
brake disk.

Figure 10

Remove O-ring (see arrow).

Figure 11

Use the pry bar to lift the shaft seal on the brake disk side out of
the hub hole.

(S) Pry bar 5870 345 071

Figure 12

5871 216 002 1/3

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Remove compact bearing (see Figures 13 to 17)

) Incompact
the following cases it is also necessary to check the
bearing inside. Grease change shall be necessary:
• As part of the maintenance interval, see List of
Lubricants TE-ML 12.
• In case of grease leakage on the shaft seal of the
brake disk side or when replacing the shaft seals.
• In case of overheated brake parts (e.g. burnt
pressure piece – bellows)

Grease to be disposed of ecologically and according to the

legal requirements!
1
Legend to Figure 13:
3 1 = Hub
2 = Compact bearing
2 3 = O-ring
4 = Retaining ring
4 5 = Hub carrier
5

Figure 13

Unsnap retaining ring (see arrow).

Figure 14

Remove bearing inner ring on the brake disk side.

) Mark bearing inner ring and the corresponding bearing

outer ring. Bearings are paired and can by no means be
mixed up!

Figure 15

5871 216 002 1/4

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Use a lever to remove the outer shaft seal from the hub hole.

Figure 16

Remove the releasing bearing inner ring.

If necessary, remove both bearing outer rings out of the hub.

) Mark bearing inner ring and the corresponding bearing

outer ring. Bearings are paired and can by no means be
mixed up!

Figure 17

Remove tachometer and clamping sleeve (see arrow) from the

carrier.

Figure 18

Secure the hub carrier with the lifting device.

Loosen threaded connection and separate the hub carrier from

the axle housing/portal housing.

(S) Eye bolt set 5870 204 002

(S) Eye nut 5870 281 054

Figure 19

5871 216 002 1/5

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

If necessary, remove carrier (1) and closing cover (2).

Comment on sketch:
2 1 = Carrier
2 = Closing cover

Figure 20

5871 216 002 1/6

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

2. Reassembly output and hub carrier

Press the carrier with the pressing fixture onto the hub carrier.

(S) Pressing fixture 5870 506 162

) For reassembly wet the bearing seat with Loctite

(Type no. 574).
Pay attention to installation dimension X 4+1 mm and
installation position tachometer diameter hole – 6’o clock
position– (see arrow Figure 2)!
When using the specified special tool you will obtain the
Figure 1
exact installation dimension!

Legend to the sketch 2:

2
1 = Carrier
2 = Closing cover
1

Figure 2

Insert the closing cover into the hub carrier hole until contact
position is obtained (see also Figure 2).

Figure 3

Fix the hub carrier with the lifting device to the axle housing /
portal housing.

Tightening torque (Torx screws) MA= 185 Nm

Tightening torque (cyl. screws) MA= 200 Nm

(S) Eyebolt set 5870 204 002

(S) Eye nut 5870 281 054

) For a threaded connection version with cylindrical screws it

is necessary to mount washers= 3.0mm. This is not
applicable for the Torx –screw version.

Figure 4

5871 216 002 2/1

 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Mount the clamping sleeve into the carrier until contact is

obtained.
See also sketch Figure 7.

) Before assembling the clamping sleeve, apply UNIREX N3 to

the entire surface of the carrier plate hole.

Figure 5

Mount the tachometer until the plane face (see arrow) of the
carrier. See also sketch Figure 7.

Then fix the tachometer cable (route generously by making a

loop) to the clamp.

) Mount speed sensor, applying UNIREX N3 throughout the

entire surface of the metallic section.
Installation radius of the speed sensor cable min. radius
15 mm or bending radius larger than 90°.
For the alternating bending stress due to the motion of the
Figure 6 bending positions the min. permitted bending radius is
60mm.

Legend to the sketch 7:

1 1 = Hub carrier
2 = Carrier
3 = Tachometer
3 4 = Clamping sleeve
5 = Clamp
4
5
2 Pay attention to the installation position of the tachometer!
Connection plug black Driving direction left
Connection plug orange Driving direction right
Figure 7

Press the wheel bolts into the hub until contact is obtained.

Alternatively it is also possible to mount individual wheel bolts

with the subsequent special tools.

(S) Wheel bolt puller– basic device 5870 610 010

(S) Insert M 22x1.5 5870 610 002

Figure 8

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Press the bearing outer rings on both sides into the hub until
contact is obtained.

(S) Driver tool 5870 050 007

(S) Handle 5870 260 004

Figure 9

Grease compact bearing in the marked area - - - .

Total grease quantity of each output side: 117 to 128g.

) Richly grease the bearing rollers inside and outside as well as

on the front sides!
Do not use grease types other than those approved by ZF
(e. g. Renolit LX-NHU 2, ZF order no.: 0671 190 177).
The binding ZF List of Lubricants is TE-ML 12!
The latest update of the List of Lubricants is available at
internet site [Link] Service/Techn. Information !

Figure 10

Mount bearing inner ring on brake disk side (with groove for
O-ring on the inner diameter) onto the arbor.

(S) Arbor 5870 345 121

Then hook the retaining ring into the annular groove of the
bearing inner ring.

) Toring,ensure the preciseness for engagement of the retaining

it is necessary to use the arbor.

Figure 11
) When changing grease - - hub mounted to the brake disk the
bearing inner ring on the brake disk side must also be
supported with the arbor!

Install the hub onto the bearing inner ring.

Figure 12

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 Off-Road Driveline
Repair Manual Technology and Axle
Systems Division

Insert the outer bearing inner ring into the hub and then engage
the retaining ring with an appropriate mandrel.

) Tothe ensure the exact contact position of the bearing rollers in

bearing outer ring:
Press bearing inner ring firmly and rotate several times
(rolling in)!

Figure 13

Legend to Figure 14:

1 = Outer shaft seal
2 2 = Shaft seal on brake disk side
1
3 = Tapered roller bearing on brake disk side
4 = Outer bevel roller bearing
5
5 = Retaining ring

) In= 140
case of correct location the reference dimension is
+/- o,4
mm , see sketch!
4
) It is no more possible to lift the outer bearing inner ring!
140±0,4mm 3

Figure 14

Mount the outer shaft seal.

(S) Driver tool side „B“ 5870 051 053

) The use of the specified special tool (S) ensures that the
installation depth is precise!
Pay attention to the installation position – designation
„AUSSENSEITE / OUTSIDE“ showing upwards (outside)!

Figure 15

Mount shaft seal on brake disk side.

(S) Driver tool page „A“ 5870 051 053

) The use of the specified special tool (S) ensures that the
installation position is precise!
Pay attention to the installation position – sensor ring shows
upwards (outside) or designation „FETTSEITE /
GREASESIDE“ shows to the bearing inner ring!

Figure 16

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Mount hub into brake disk and use the press to fix with
appropriate mandrel.

Then bolt hub – brake disk.

Tightening torque
Torx screws M14x1.5/10.9 MA= 190 Nm

Tightening torque
Hexagon screws M16x1.5/10.9 MA= 300 Nm

Bild 17

Apply lubricant „MOLYKOTE DX“ to the entire surface of both

bearing seats.

Figure 18

Insert inner installer into the hub carrier until contact is obtained.

(S) Inner installer 5870 651 085

Figure 19

Grease O-ring and insert it into the bearing inner ring (see arrow)
of the brake disk side.

Figure 20

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Mount preassembled hub carefully with the lifting device to the

hub carrier until contact is obtained.

Then remove the inner installer again.

(S) Lifting bracket 5870 281 043

Figure 21

Mount internal slotted nut:

Pretighten slotted nut with 100 Nm. After that rotate the hub
several times in both directions. Then tighten the hub to the final
tightening torque.

Tightening torque (inner slotted nut) MA= 850 Nm

(S) Slotted nut wrench 5870 401 146

) Pay attention to the installation position:

Mount the slotted nut with the chamfer showing outwards!
Figure 22
) While tightening rotate the hub several times in both
directions!

If no increase of the bearing rolling torque or axial play of

the wheel bearing is noticeable (Figure 22) while tightening,
it is possible that this may be caused by unsnapping of the
retaining ring (see Figure 13/14) of the compact bearing.

Correct assembly fault, if necessary.

Figure 23

Insert locking plate and assemble outer slotted nut.

Tightening torque (outer slotted nut) MA= 1200 Nm

(S) Slotted nut wrench 5870 401 146

) Pay attention to the installation position:

Mount the inner securing clip of the locking plate showing
inside.
Mount the chamfer of the slotted nut also showing inside!

Figure 24

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Secure slotted nut by fixing the locking plate to a nut of the outer
slotted nut.

Figure 25

Grease O-ring and insert it into the annular groove of the cover.

Figure 26

Support hub to avoid rotation.

Insert the cover until contact is obtained and fix with hexagon
screws.

Tightening torque (M18x1,5) MA= 100 Nm

Figure 27

Carefully insert (manually) the tachometer until contact with the

impulse disk of the shaft seal is obtained.
3
Legend to Figure 7:
1 = Hub carrier
2 = Carrier
3 = Tachometer
4 = Shaft seal (with impulse disk)
2
4
1
) For tachometer alignment rotate the hub several times.
Light scratching noises are normal.

Figure 28

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Brake reassembly

Tightening torque (M16x1.5 / 10.9) …….. MA = 270 Nm

(with tight-fit screw)
Tightening torque (M18x1.5 /10.9) ………MA = 440 Nm

) The fitting screw must always be mounted on the left and

right output side in driving direction (front side)!

When working on the brake system, the instructions and

specifications of the respective brake manufacturer are
Figure 29 binding!
The relevant information is included in the repair and
maintenance instructions of the component manufacturer!
The latest updates of the individual instructions can be
ordered by the brake manufacturer or looked up at the
available internet site!
Brake manufacturer and brake type can be taken from the
identification plate of the brake caliper.

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3. Axle housing/Portal housing

This chapter provides a description of the different axle housing

versions. Axle housings and the related components have
different forms and versions, depending on the corresponding
parts list.
In case of repair please use the information corresponding to
your part list.

3.1 One piece standard version

If necessary, replace identification plate.

) The identification plate is applied with Loctite

Type no.: Terostat-MS 9360 on all axle housing versions.

Figure 1

2 3 3.2 One piece with bolted bracket

1 Legend to Figure 2:
1 = Cylindrical pin
2 = Cylindrical screw
3 = Bracket
4 = Axle housing

In case of repair replace the cylindrical pin (1).

4 Fix bracket (3) with the cylindrical screws (2) to the axle
housing (4).
Figure 2
Tightening torque MA= 440 Nm
Cylindrical screws M18x1.5/10.9

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2 3.3 Multi-part with retaining plate (Version 1)

3 Legend to Figure 2:
4
1 = Axle housing
4
2 = Portal housing
3
3 = Retaining plate
4 = Torx screw

1 Apply retaining plate (3) when fixing the portal housing to the
axle housing as shown on the Figure.
2
Fix the portal housing (2) with the Torx screws (4) to the axle
Figure 3 housing.

Tightening torque MA= 185 Nm

Torx screws M14x1.5/10.9

3.4 Multi-part with retaining plate (Version 2)

3 Legend to Figure 2:
4 1 = Axle housing
3 4 2 = Portal housing
3 = Retaining plate
4 = Torx screw/ cylindrical screw
2
Apply retaining plate (3) when fixing the portal housing (2) to
1 the axle housing (1) as shown on the figure.
2 Fix portal housing (2) with screws (4) to the axle housing (1).
Figure 4
Tightening torque MA= 185 Nm
Torx screws M14x1.5/10.9

Tightening torque MA= 200 Nm

Cylindrical screws M14x1.5/10.9

) Ifcylindrical
axle housing/portal housing have been bolted with
screws, it is imperative to mount washers.

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3.5 Multi-part drive axle housing

Legend to Figure 2:
1 = Axle housing
2 = Portal housing
3 = Closing cover
4 = Torx screw
5 = Stud bolt
6 = Hexagon nut
7 = Disk

If necessary, flush-mount the closing cover (3) into the axle

Figure 5 housing (1).

5 ) Pay attention to the installation position!

Mount the collar showing outwards!

Insert the stud bolts to the hole bottom of the portal housing on
the input side. (Position see Figure 6)

) Wet stud bolts with Loctite (Type no. 243) for installation
into the portal housing.

5
Fix portal housing (2) with Torx screws (4) to the axle housing
Figure 6 (1).
Mount disks (7) to the stud bolts and fix them with hexagon nuts.

Tightening torque MA= 200 Nm

Hexagon nut M14x1.5

Tightening torque MA= 185 Nm

Torx screws M14x1.5/10.9

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4. Components

This chapter provides a description of the different component

versions. They can have different form and version, depending
on the corresponding parts lists.
In case of repair please use the subsequent information as
needed.

4.1 Overview

2 2 Legend to Figure 1:
7 7
1 = Spring carrier
2 = Brake cylinder
3 = Bracket
4 = Longitudinal rod
5 = Longitudinal rod
6 = Air spring
1 1 7 = Shock absorber

6 6

) Detailed information regarding reassembly of the

individual components is provided as of Figure no. 2.
5 5
7 7 For components which are not mounted or supplied
1 4 4 1
by ZF, please contact the vehicle manufacturer for
further information, e.g. tightening torques,
3 3 components, etc.

Note:
The axle view displayed on Figure 1 does not show the
2 2
axle version with stabilizer link (track guidance system).
These are described separately on page 4/4.
1 1
7
7

6 6

2
3 7
5
7
6 6

1 4 1
Figure 1

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4.2 Description of components

Mount two adjusting screws for positioning the spring carrier.
Then fix spring carrier (1) to portal housing / axle housing with
hexagon screws (see arrows) and fix washers.
Remove adjusting screws and mount the remaining hexagon
screws and washers.
1
Tightening torque MA= 620 Nm
Hexagon screws M20x1.5/10.9

(S) Adjusting screw 5870 204 044

Figure 2

Fix brake cylinder (2) with locknuts (see arrows) to the brake.
2 Tightening torque MA= 195 Nm
Locknut M16x1.5

Figure 3

3 Place longitudinal rod bracket (3) to portal housing / axle

housing.
Hand-tighten the cylindrical screws on the longitudinal rod side
with the mounted washers (see arrow) (3 to 5 Nm).
Then tighten the lateral cylindrical screws to the specified torque.
Retighten the cylindrical screws on the longitudinal rod side also
to the specified torque.

Tightening torque MA= 440 Nm

Cylindrical screws M18x1.5/10.9

Figure 4

Mount one adjusting screw on each longitudinal rod fixation for

positioning, then fix upper longitudinal rod (4) and lower
longitudinal rod (5) accordingly with hexagon screws.
5 5 Remove adjusting screw and mount the remaining hexagon
screw.
4 4
Tightening torque MA= 390 Nm
Hexagon screws M18x1.5/10.9

(S) Adjusting screw 5870 204 029

Figure 5
) At the rear end lift longitudinal rod for fixing!

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Fixation air spring (Version 1)

Fix air spring with hexagon nut (see arrow) to the spring carrier.

Tightening torque MA= 70 Nm

6 Locknut M18x1.5

) For assembly wet thread with Loctite type no. 243.

Figure 6

Fixation air spring (Version 2)

Fix air spring with hexagon screw (see arrow) to the spring
carrier.

Tightening torque MA= 90 Nm

6 Hexagon screw M18x1.5/8.8

) For assembly wet thread with Loctite type no. 243.

Figure 7

6 Fixation air spring (Version 3)

1 Legend to Figure 1:

1 = Disk
5 2 = Threaded pin
3 = Disk
4 = Hexagon nut
6 3 5 = Spring carrier
4 6 = Air spring
2

Figure 8 Mount components as shown on the sectional drawing of

Figure 8.

Tightening torque MA= 34 Nm

Threaded pin M10

Tightening torque MA= 46 Nm

Hexagon nut M10

) For assembly of the threaded pin and the hexagon nut wet
the threads accordingly with Loctite type no. 243.

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Fix shock absorbers (7) to the spring carrier (1) as shown on the
sectional drawing.
7
Tightening torque MA= 60 Nm
1
Hexagon nut M14x1.5

Figure 9

4.3 Axle version with

stabilizer link
(track guidance system):

Figure 10

Legend to Figure 10:

1 = Torso axle 8 = Hexagon screw (M24x1.5x90/10.9) MA = 1100 Nm

2 = Spring carrier le/ri. 9 = Disk
3 = Hexagon screw (M20x1.5x55/10.9) MA = 620 Nm 10 = Slotted pin
4 = Disk 11 = Slotted pin
5 = Spring carrier le. / ri. 12 = Complete stabilizer link consisting of:
6 = Hexagon screw (M20x1.5x70/10.9) MA = 620 Nm Axial joint (2x) ………………. MA = 600 Nm
7 = Disk Tube with clamps………. MA = 50 Nm

Note on pos. 10 / 11:

Mount the slots of the slotted pins in a 180 ° offset position to each other!

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Setting stabilizer link:

- Wet the thread of the ball heads with Loctite type no. 243 for assembly into the spring carrier.

- Fix ball heads to spring carriers. MA = 600 Nm

- Turn the supporting rod tube to the center of the axle. (Distance of tube end to ball joint contact (le. - ri.) max. 4 mm)!

- Fix one clamp to the supporting rod . MA = 50 Nm

- Keep in position on the clamped ball joint side of the hexagon screw.

- Tighten the non-clamped joint side to pressure (between spring carriers). MA = 50 Nm

- Tighten second clamp. MA = 50 Nm

Caution!
Once a year it is necessary to verify that the supporting rod has zero backlash and readjust, if required!

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