6 - Rear Axles

DAILY EURO 4 REAR AXLES 1
SECTION 6
5250 Rear axles
Page
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR AXLE NDA RS . . . . . . . . . . . . . . . . . . . . . 5
REAR AXLES NDA RG . . . . . . . . . . . . . . . . . . . . 35
REAR AXLE 450511 . . . . . . . . . . . . . . . . . . . . . . 53
REAR AXLE 450517/2 . . . . . . . . . . . . . . . . . . . . 83
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Print 603.93.651 Base - March 2006

2 REAR AXLES DAILY EURO 4
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Base - March 2006 Print 603.93.651

DAILY EURO 4 REAR AXLES 3
DIAGNOSTICS
The main rear axle operating faults are as follows:
1. - Wheel hubs noise;

2. - Rear axles noise;
3. - Noise at release;
4. - Noise during acceleration;
5. - Cornering noise.
1 WHEEL HUBS NOISE
Insufficient lubrication. Check that there are no leaks from gaskets or the rear
YES axle casing and top up oil to correct level.
NO
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Wheel hub bearings inefficient. Remove the hub and replace inefficient parts.
YES
NO
Wheel hub bearings out of adjustment. Adjust bearings.

YES
2 REAR AXLES NOISE
Lubricating oil level low. Check that there are no leaks from gaskets or the rear
NO
Drive shaft splines to fit the differential crown wheels Overhaul the rear axle and replace worn or damaged
damaged. YES
parts.
NO
Wheel hub bearings inefficient. Adjust the bearings clearance.

YES

4 REAR AXLES DAILY EURO 4
Bad adjustment or wear on differential gears or bearings. Locate the trouble and overhaul the unit.
YES
3 NOISE AT RELEASE
Improper fitting clearance between pinion and ring bevel Remove the gear housing inspection cover and adjust
gear. YES clearance between pinion and ring bevel gear.
4 NOISE DURING ACCELERATION
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Insufficient lubrication. Check that there are no leaks from gaskets or the rear
NO
Gear housing bearings badly set or deteriorated. Overhaul the unit.

YES
NO
Bad tooth contact between pinion and ring bevel gear. Adjust the contact.
YES
5 CORNERING NOISE
Improper clearance between planetary gears and crown Overhaul or replace the unit.
wheels. YES

DAILY EURO 4 REAR AXLE NDA RS 5
Rear axle NDA RS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS AND DATA . . . . . . . . . . . . . 8
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REAR AXLE NDA - RS REMOVAL - REFITTING 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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OVERHAULING THE REAR AXLE ASSEMBLY . 19
- Air breather disassembly - assembly . . . . . . . . 19
- Wheel hub overhaul . . . . . . . . . . . . . . . . . . . . 19
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REPAIRING THE DIFFERENTIAL . . . . . . . . . . . . 22
- Disassembling the differential unit . . . . . . . . . . 22
- Gear housing removal . . . . . . . . . . . . . . . . . . . 23
- Dismounting bevel pinion . . . . . . . . . . . . . . . . 24
- Checking the parts comprising the differential 25
- Assembly of gear housing . . . . . . . . . . . . . . . . 26
- Assembling the bevel pinion assembly . . . . . . 27
- Assembly of differential unit . . . . . . . . . . . . . . 30

6 REAR AXLE NDA RS DAILY EURO 4
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DESCRIPTION The adjustment of bearing rolling torque is through adjusting

rings put in between box and stop rings.
The rear axle is the load-bearing type with a single reduction
using a hypoid crown wheel and pinion. The clearance between pinion and crown wheel is adjusted
by changing the thickness and/or position of the adjustment
The axle housing is made of pressed sheet steel with hot
rings, though the total thickness must be the same as that of
pressed arms.
the adjustment rings removed.
The bevel pinion is supported by two pre-lapped tapered
Differential wheelwork assembly is made up of two planetary
roller bearings to hold the bearing pre-load better.
and two crown wheel gears.
The bearings are factory lubricated by the manufacturer with
The drive shafts are supported inside the arms of the axle
rustproof protective oil.
housing by UNIT BEARINGS lubricated for life, which require
The rolling torque of the bearings of the bevel pinion is no adjustment.
adjusted by changing the thickness of the adjustment ring
The brakes are disc brakes with floating brake calipers.
between the two tapered roller bearings.
The disc brakes are splined onto the end of the drive shafts
In addition, it is possible to adjust the position of the bevel
and secured with pins that also serve as centring for the
pinion with respect to the ring bevel gear by changing the
wheel rims.
thickness of the ring between the axle housing and the bevel
pinion rear bearing external ring. The brake calipers are secured with flanges welded onto the
end of the arms of the axle housing.
The gear housing is supported by two tapered roller bearings,
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also pre-lapped and lubricated with rustproof protective oil. The brake calipers are equipped with the parking brake
device.
Figure 1
107834

SPECIFICATIONS AND DATA
Type of rear axle:

NDA RS
Simple reduction type
DIFFERENTIAL UNIT
1/3,154 (13/41) - 1/3,416 (12/41) - 1/3,727 (11/41) - 1/3,916

Reduction bevel gear pair ratio
(12/47) - 1/4,182 (11/46) - 1/4,444 (9/40) - 1/4,889(9/44) -
(No. of teeth: pinion/crown)
1/5,111 (9/46)
Bevel pinion bearings 2 with taper rollers
Bevel pinion bearings rolling torque

(bearings lubricated and without
gasket) Nm 2.3 ÷ 3.3
New bearings
kgm 0.23 ÷ 0.33
Adjustment of pre-load of bevel
By means of adjustment rings
pinion bearings
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Bevel pinion bearings pre-load 0.545 ÷ 1.070 mm
> adjustment rings with progression of 0.025 mm.
Temperature at assembly of inner
-
bearing ring on bevel pinion
Position of bevel pinion with

By means of adjustment spacers
respect to differential casing
Thickness of adjustment rings 3.585 ÷ 4.235 mm

> placed between bevel pinion and
differential casing with progression of 0.025 mm.
Bearings for gear housing 2 with taper rollers
Differential casing bearings rolling

torque (bearings lubricated and
without gasket)
- 15/44 - 13/41- 12/41
- 12/43 - 12/47 - 10/41:
Nm 2.7 ÷ 3.9
kgm 0.27 ÷ 0.39
- 11/49 - 9/40 - 9/44
- 8/41 - 8/45:
Nm 2.6 ÷ 3.7
kgm 0.26 ÷ 0.37
Adjustment of differential casing

bearings rolling torque
Thickness of adjustment rings of 1 ÷ 1,95 mm

> differential casing bearings rolling
torque with progression of 0.05 mm.

Type of rear axle:

NDA RS
Clearance between pinion and ring
bevel gear with reduction ratios
- 1/3.916 - 1/4.182 - 1/4.444 -
0.13 ÷ 0.18 mm
1/5.111:
- 1/3.154 - 1/3.416 - 1/3.727 -
0.15 ÷ 0.20 mm
1/4.889:
Adjustment of clearance between

pinion and ring bevel gear
Clearance between planetary and

0.05 ÷ 0.15 mm
crown wheels
WHEEL HUBS
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Wheel hub bearings UNIT-BEARING
Wheel hub bearings end play -
Wheel hub bearings rolling torque

Nm -
kgm -
Adjustment of wheel hub bearings Not adjustable

end play Tighten fixing ring nut to torque
Rear axle oil TUTELA W90/M-DA (SAE 80 W 90)

Quantity Litres 1,35
Dry rear axle weight :
- With ABS kg 112.1
- Without ABS kg 110.6
- Max capacity (GAW) kg 2240

TIGHTENING TORQUES
Figure 2
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107835
NDA RS REAR AXLE DIFFERENTIAL SECTION
PART TORQUE
Nm Kgm
1 Bevel pinion retaining nut 400 ÷ 500 40 ÷ 50
2 Screw securing half-housing and ring bevel gear 89 ÷ 108 8.9 ÷ 10.8
3** Oil filler plug 49 ÷ 62 4.9 ÷ 6.2
4 Screw securing caps to differential housing 100 ÷ 120 10 ÷ 12
5 Screw securing gearing inspection cover to the axle housing 80 ÷ 95 8 ÷ 9.5
*** Oil drainage plug 49 ÷ 62 4.9 ÷ 6.2
* = Apply LOCTITE 5910 on the housing
** = Apply LOCTITE 577 on the plug thread
*** = Apply LOCTITE 573 on both sides of the gasket

Figure 3
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107836
NDA RS REAR AXLE DIFFERENTIAL SECTION

Figure 4
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107837
NDA RS REAR AXLE WHEEL HUB SECTION
TORQUE
PART
Nm Kgm
1 Wheel securing screw 160 16,3
2 M8x1.25 brake disk securing screw 13 ÷ 21 1,3 ÷ 2,1
3 M52x3 half shaft bearing securing ring nut 559 ÷ 677 57,0 ÷ 69,0
4 M12 rear axle arm - bearing support securing screw 125 ÷ 135 12,7 ÷ 13,8
5 M14x1.5 brake caliper securing screw 176 ÷ 217 17,9 ÷ 22,1
- M6 metal sheet guard securing screws 10 ÷ 16 1,0 ÷ 1,6

TOOLS
TOOL NO. DESCRIPTION
99305121 Hot air drier
99322215 Front and rear axle overhaul stand
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99341003 Single-acting rear axle
99341009 Pair of brackets
99341011 Pair of brackets
99341015 Clamp

TOOLS
99345057 Extractor reaction block
99348001 Extractor with locking device
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99355184 Shaft bearing ring nut wrench
99370006 Handle, interchangeable drift
99370007 Grip for interchangeable punches
Tool to determine thickness of adjustment of bevel pinion

99370239 (use with 99395728)

TOOLS
99370241 Tool for fitting drive shaft bearing
99370317 Reaction lever with extension for flange retaining
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Universal mounting to support axles during removal and refitting
99370617
99372236 Tool to move brake caliper piston back
Key to fit differential bevel pinion gasket (use with 99370007)

99374022
Punch to fit external races of bearings (diameter 55 ÷ 69 mm use

99374091 with 99370007)

TOOLS

99374092 with 99370007)
99389819 Dynamometric wrench (0 ÷ 10 Nm) with 1/4” square connection
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Dial gauge with mounting to be used with the tools to determine
99395728 the thickness of adjustment of the bevel pinion

525010 REAR AXLE NDA - RS REMOVAL - Figure 5

REFITTING
Removal
Position the vehicle on level ground and stop front wheels.
Loosen rear wheels securing screws.
Lift the vehicle from its rear side and position it on support
stands.
Position hydraulic truck under rear wheels. Remove wheels
securing screws and take them off the vehicle.
Unscrew nut (2) adjusting hand brake linkage. Release the
cables from the chassis by uncoupling check springs (1).
Unscrew screws (7) securing transmission shaft (8).
Disconnect electrical cables (15) of the sensors of brake pad
wear and phonic wheel rpm’s (6).
Unscrew nuts (12) securing shock absorbers (11).
Take hydraulic pipes (16) of brake system off the fitting on the
chassis. Such pipes will be removed together with real axle in
the end step of the disconnection from the vehicle.
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In disconnecting the hydraulic pipes of brake circuit
! and vapours breather, pay attention to any oil losses.
Prearrange suitable collectors in such a way that
brake liquid is not spread out into environment.
Avoid contact of liquid with skin and eyes. In case of
contact, wash abundantly with water.
Unscrew screws (3) securing rods (4) supporting stabilising bar

(5).
Disconnect rear axle oil vapours breather pipe (20).
Properly position a hydraulic jack provided with support
99370617 under rear axle.
Unscrew nut (17) securing leaf spring (9) to rod (18).
Unscrew nuts (13) of brackets (14) securing rear axle to leaf
springs (9).
Lower hydraulic jack and take out rear axle.
Refitting
For refitting, carry out the operations described for removal in
reverse order, taking the following precautions:
- Check the thread of the brackets joining the leaf springs to
the axle. If there are any irregularities, rectify the thread
(operation 500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described
under the relevant heading (operation 784010).
- Adjust the handbrake control ties as described under the
relevant heading (operation 502710).
- Lock the nuts or screws to the required tightening torque.
- The self-locking nuts must not be reused.
108434
- The lubricating oil in the axle housing should be at the right
level.
- Check the state of the flexible pads (19) and replace them
if they have deteriorated (operation 500417).

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525010 OVERHAULING THE REAR AXLE 525030 Wheel hub overhaul

ASSEMBLY Disassembly
Figure 8
The drive shafts, brake disc and calipers, air breather
! and differential can all be removed and refitted even
with the unit mounted on the vehicle.
Before positioning the rear axle assembly on the stand for

overhauling, drain off the oil by unscrewing the side plug of
the axle housing.
Figure 6
107985
Take out the screws (1) and remove the brake caliper (2)
with its brake linings from the mounting.
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The caliper must not be violently knocked or
! dropped.
Prevent the rubber caps coming into contact with
sharp metal tools.
Do not dirty or wet the rubber caps with mineral grease or
oil.
107853
Do not dirty the pads with liquids or grease.
Set the entire rear axle assembly on stand 99322215.
Do not operate the parking brake lever before mounting on
the disc: this makes the piston come out, decreasing the gap
The identification data of the rear axle unit are given between the two brake linings and jeopardizing wearability on
! on the plate (1) fixed near to the leaf spring the disc.
attachment support. Should this be done unexpectedly, it is necessary to take
down the brake linings and move the piston back with tool
99372236, taking the precautions given in the BRAKES
section.
525013 Air breather disassembly - assembly

Figure 9
Figure 7
107855
Remove pin (1) centering/securing brake disk (2) to half shaft

(3). Take off brake disk (2).
107854
Check that the air breather (1) is not clogged; otherwise, NOTE Check brake disk as described in Brakes section. On
disassemble and clean it thoroughly before refitting. putting away the brake disk, do not damage phonic
wheel toothing.

Figure 10 Figure 13
107986 107989
Unscrew securing screws (2) and take out half shaft Properly arrange half shaft (1) on hydraulic press and take out
comprehensive of unit-bearing support (1), bearing, ring nut bearing (2) together with support (3). Using extractor
and metal sheet guard (3). 99348001 (4).
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Figure 11 Figure 14
107987 107990
Tighten half shaft (1) in a vice. Unscrew screws (2) securing metal sheet guard (1) to
Remove denting (→) of ring (2) engaging in ring nut (3). support (3). Pull guard apart from support.
Figure 12
107988
Using wrench 99355184 (1), unscrew ring nut (2) checking

bearing (3) to half shaft (4).

Assembly Figure 17
Figure 15
108042
Put assembled half shaft into rear axle box. Tighten screws
(1), securing half shaft to rear axle arm, at prescribed torque.
108040
Arrange tool 99370241 (4) on the press and position bearing
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(3) and support (2) comprehensive of metal sheet guard on
the tool.
Put in half shaft (1) and, by the press (driving load
3300÷18000 N), put it into up to ledge.
Figure 18
NOTE The bearing (3) must not be heated.
107855
Figure 16
Mount brake disk (2) on half shaft (3) and tighten securing
pin (1) at prescribed torque.
108041
Mount the assembly on a vice.

Thread washer (2) and ring nut (1).
Using wrench 99355184 (3), tighten ring nut (1) at
prescribed torque.
Dent washer (2) on milled portion of ring nut (1) as indicated
in figure.

Figure 19 Figure 21
107985
108043
NOTE The brake lining with the wear indicator must be Mark the position of the caps (1 and 2), take out the screws
mounted on the piston side of the brake caliper. (3) and remove them.
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Rest the brake caliper (2) with the brake linings on the
mounting.
NOTE Should brake calliper piston be moved backward,

use tool 99372236 and follow the
recommendations set out in the BRAKES section.
Figure 22
Tighten the screws (1) securing the caliper (2) to the
required torque.
After assembly, fill the axle housing with TUTELA W90/M -
DA oil in the required quantity and grade.
526210 REPAIRING THE DIFFERENTIAL
Disassembling the differential unit
NOTE Before repairing the differential it is necessary to

drain off the oil and dismantle the drive shafts, as
described under the heading of overhauling the
wheel hub (operation 525030).
Figure 20 108044
Take differential box (1), comprehensive of ring gear,

wheelwork, bearings (2-5), adjusting shims (4) and rib rings
(3), out of rear axle box.
NOTE Write down the positions of adjusting shims, rib

rings and bearing outer rings in order to be able to
107838 arrange them according to original configuration
Unscrew screws (1) complete with safety washers and take on mounting step.
off wheelwork inspection cover (2).

Gear housing removal Figure 24

Figure 23
51818 108045
Use tool 99341003 (1), brackets 99341009 (2), clamp Unscrew screws (3) and remove bevel wheel (1) from
99341015 (3) and reaction block 99345057 (4) to remove differential box (2).
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taper roller bearing inner rings (5 - 7) from gear housing (6).
Figure 25
108046
Using a proper beater, remove spring peg (1) and unthread planetary gear holder pin (9).
Rotate crown wheels (6 and 10) in such a way as to have planetary gears (3 and 7) matching the slits on differential box (4).
Remove planetary gears (3 and 7) and relating thrust blocks (2 and 8) from differential box (4).
Remove crown wheels (6 and 10) and relating rib thrust blocks (5 and 11).

Dismounting bevel pinion Figure 29

Figure 26
108050
108047 Remove the seal (1) and the internal ring (2) of the front
Lift denting (1) checking nut (2). bearing.
Using tool 99370317, stop the rotation of flange (3).
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Unscrew and remove nut (2).
Figure 27 Figure 30
108048 107839
Take flange (1) out of bevel pinion (2). Use a punch to remove the external rings (3 - 4) of the
Should flange (2) be too difficult to remove, single-acting rear tapered roller bearings from the axle housing (1) and take out
axle 99341003 coupled to bracket pair 99341009 can be the adjustment shim (2).
used as an extracting assembly.
Figure 31
Figure 28
108049 74727
Using a proper beater, beat according to direction indicated With axle 99341003 (2), brackets 99341011 (1), press
by the arrow until bevel pinion (1) complete with rear 99341015 (5) extract the internal ring (3) on the bevel pinion
bearing, fixed spacer and adjusting nut is ejected from rear (4).
axle box (2).

Figure 32
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107840
DIFFERENTIAL UNIT COMPONENTS

1. Nut - 2. Transmission connection flange - 3. Gasket - 4. Front bearing - 5. Bearing adjusting shim - 6. Spacer - 7. Ledge ring -
8. Rear bearing - 9. Bevel pinion - 10. Ring bevel gear - 11. Rib ring -12. Adjusting ring - 13. Taper roller bearing -
14. Differential box - 15. Crown wheel rib thrust block - 16. Crown wheel - 17. Planetary gear rib thrust block - 18. Planetary
gear - 19. Pin - 20. Screw securing ring gear / differential box
Checking the parts comprising the differential

NOTE If it is necessary to replace the ring bevel gear or
pinion, replace both parts since they are supplied
Carefully clean the single components of the differential in pairs.
locking.
Lubricate the bearings and rotate the roller cage freely;
rotation must be even and without signs of stiffness. Check Check planetary gears with relating rib thrust blocks, pin and
the support surfaces of the ring bevel gear and the striking crown wheels with rib thrust blocks.
surface of the half-casing so that the ring bevel gear fits Replace all the sealing elements, the bevel pinion retaining
perfectly. Deformations of such parts, could determine nut and the gear housing bearing adjustment ring nut with
vibration of the ring bevel gear fastening screws, thus new parts.
compromising the perfect operation of the unit.
NOTE Carefully clean all the threads in order to obtain

exact adjustments and accurate tightening torque. NOTE The tapered roller bearings are supplied as spare
parts, lubricated with rustproof oil.
They must not be washed or heated for assembly.
Check for grooved section for keying the flange on the pinion The differential housing support bearings must
not being excessively worn out. Otherwise, replace the both be from the same supplier.
pinion.

Assembly of gear housing

Figure 33
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108046
Put crown wheels (6) and (10), complete with rib rings (5) and (11), into seats inside differential box (4).
Through the slits on box (4), position planetary gears (3) and (7), complete with rib thrust blocks (2) and (8), in order them
to contact crown wheels (6) and (10).
Rotate crown wheels in such a way that the holes of planetary gears are aligned to guide holes for pin (9) that are present on
the box of differential (4).
Thread pin (9) aligning the hole for spring peg (1) to the hole that is present on the box of differential (4).
Using a proper beater, put spring peg (1) into its seat.
Figure 34 Figure 35
108045 108404
Tighten screws (3), for matching between bevel wheel (1) Using a proper beater, mount inner ring (1) on wheelwork
and the box of differential (2), at prescribed torque. box (2).
Repeat operation for outer ring (3).

Assembling the bevel pinion assembly Figure 39

Figure 36
108405 101977
Using the punch 99374091 (3) and grip 99370006 (4), mount Mount provided washer (3) and inner ring (2) of taper roller
the external ring (2) of the tapered roller bearing in the axle bearing on dummy pinion 99370239 (1).
housing (1).
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NOTE New bearings are lubricated with rustproof oil and
must therefore not be washed or heated for
assembly.
Figure 37
Figure 40
108406
Set adjusting ring (4), removed at disassembling, into rear axle

casing (5).
Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.
Figure 38
108409
Position dummy pinion 99370239 (1), assembled as in Figure

39, on the outer ring of taper roller bearing (2).
On the opposite side, fit the taper bearing internal ring (3)
on the dummy pinion (1) and the transmission shaft flange
18241 (4) .
On a surface plate (2), zero a dial gauge (1) set on the Screw nut (5) until dummy pinion is freely rotating without
mounting 99395728 (3) and pre-load it slightly. axial clearance.

.
Figure 41 Figure 42
108407 18246
Fit the mounting 99395728 (2) with the dial gauge (1) on the
dummy pinion 99370239 (3).
NOTE If the value marked on the pinion is preceded by a
positive sign (+), it must be subtracted from the
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Orientate the, previously zeroed, dial gauge so as to position
the rod on the lowest portion of the seat of the bearing value of the sum divided by two for both seats,
supporting the gear housing and note the difference A1. whereas it has to be added if it is preceded by a
negative sign (-).
Repeat the same operation on the seat of the other bearing
and note the difference A2.
Unscrew check nut and transmission connection flange.
Thickness S to be added to adjusting ring thickness (4, Unthread flange and bearing from dummy pinion.
Figure 43) used for measuring, for pinion positioning is Remove the dummy pinion with the mounting 99395728,
obtained by the following formula: dial gauge and rear bearing from the axle housing.
S = A1 + A2 − ( B)
2
A1 indicates the value measured on the right-hand seat.
A2 indicates the value measured on the left-hand seat. Figure 43
B indicates the value marked on the bevel pinion (see
Figure 42).
For example:
S = 1, 05 + 1, 10 − (− 0, 05) = 2, 15 + 0, 05 = 1,125
2 2
The result of the formula must be added algebraically to the

value of the adjusting ring used to make the measurements.
Example:
if the value of the adjusting ring used is 3.00 mm, replace with
one measuring 4.125 mm (3.00 + 1.125).
108406
If required, replace adjusting ring (4) with a new one having

the calculated thickness, after removing bearing outer ring (3)
from rear axle casing (5) by beater.
Then fit the new adjusting ring (4) into rear axle casing (5).
Using the punch 99374092 (2) and grip 99370007 (1), mount
the external ring (3) of the tapered roller bearing.

Figure 44 Figure 47
18251
108410
Using a suitable punch (1) and a hydraulic, press mount the
internal ring (2) of the tapered roller bearing on the bevel Mount the bevel pinion (1) in the axle housing so as to enter
pinion (3). the internal ring (2) of the tapered roller bearing.
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Figure 45 Beat on the top of pinion (1) until nut securing flange (3) can
be mounted.
18252
Position fixed spacer (3) and adjusting ring (2) on bevel pinion
(1).
Figure 46
Figure 48
108408
108421
Position the axle casing as indicated in the figure.
Fit the taper bearing internal ring (1) and the transmission Use tool 99370317 (2) to prevent the flange (1) from
shaft flange (2). rotating.
Position a suitable pipe (3) on the stand so that the flange (2)
and the taper bearing internal ring (1) are correctly Tighten the bevel pinion retainer nut to the required torque
supported. with a torque wrench (3).

Figure 49 Figure 51
108423 108424
Using torque meter 99389819 (1), detect bevel pinion rolling

torque. NOTE Position the caps (2) making the marks made
during disassembly coincide.
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NOTE Rolling torque must be detected at 25 ºC ambient
temperature having the pinion rotating at 50 rpm
speed, after the pinion has run 10 revolutions. Screw on the screws (1) and tighten them to the required
torque with the dynamometric wrench (3).
If the reading differs from the prescribed value, disassemble

the pinion (1, Figure 47), replace the adjuster ring (2,
Figure 45) with a ring of the correct thickness.
Refit the pinion and repeat the rolling torque check.
Assembly of differential unit

Figure 52
NOTE When fitting the differential unit, carefully comply
with the tightening torque values specified, and
make use of a torque wrench.
Figure 50
108423
Check total rolling torque using torque meter 99389819 (1).
NOTE The rolling torque must be measured at an ambient

temperature of 25°C, making the pinion turn at a
108422 speed of 50 rpm after it has made 10 turns.
Fit the differential (1) unit and support (6) bearings in the axle
casing.
Mount spacers and adjusting rings in same quantity, thickness If the value of the measurement is not as required, replace
and position as detecting on dismounting, according to the adjustment rings (3 and 5, Figure 50) with another one
following sequence: stop ring (2), adjusting rings (3 and 5) and of a suitable thickness.
stop ring (4).

Figure 53 Figure 55
Correct contact.
108427
44604
Position the dial gauge 99395728 (1) with a magnetic base
and measure the clearance between the pinion and crown
wheel on four opposite teeth of the crown wheel (2).
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The average of the measurements must equal the required Figure 56
value.
If a different clearance is found, remove the caps (3) again and
swap over the assembly position of the adjustment rings (1
and 3, Figure 50).
Should this not be sufficient, replace adjusting rings by other
rings having different thickness, on condition that total
thickness must be equal to the total thickness of the adjusting
rings that were dismounted.
This is so as not to change the total rolling torque.
Excessive contact on tooth
Using a brush, apply a thin layer of Prussian blue on ring gear bottom or flank.
teeth. Move pinion away from ring
Turn the pinion and measure the impression of the contact gear, then move ring gear
of the pinion toothing on the crown wheel toothing. close to pinion in order to
adjust clearance.
Here we illustrate the possible contacts with the corrections
to obtain precise coupling of the crown wheel and pinion. 44605
Figure 54
Figure 57
44603 Excessive contact on heel

of tooth.
A = Coupling depth E = Greater base Move the ring bevel gear
B = Crest F = Heel towards the pinion and
C = Side G = Top land then move the pinion away
D = Play H = Contact surface from the ring bevel gear to
I = Lateral surface adjust clearance.
44606

Figure 58 Figure 61
Excessive contact in the

upper part or crest of the
tooth
108426
Move pinion close to ring
gear, then move ring gear Lubricate the internal lip of the seal (1).
away from pinion in order With the key 99374022 (2) and grip 99370007 (3), mount
to adjust clearance. the seal in the axle housing.
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44607
Figure 62
Figure 59
Excessive contact on the

top land of the tooth
Move the ring bevel gear
108421
away from the pinion them
move the pinion towards Mount flange (1). Stop the rotation of flange (1) using tool
the ring bevel gear to adjust 99370317 (2).
44608
clearance. Using torque wrench (3), tighten nut checking bevel pinion
at prescribed torque.
Figure 60
Figure 63
108425
After prescribed coupling clearance has been completed,

stop the rotation of flange (1) using tool 99370317 (2). 108428
Deform the collar of the nut (1) as shown in the figure at the
Unscrew the retaining nut and extract the flange (1) from the
milling of the bevel pinion (2).
bevel pinion.

Figure 64 Figure 66
107856
108429
Thoroughly clean the flange of the axle housing. According to sequence indicated in figure, tighten the screws
at prescribed torque.
Apply LOCTITE 5910 sealant on the flange of the axle
housing to form a bead of approx. 5 mm diameter. Complete mounting operation observing the following:
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It must be uniform (no lumps), without any air bubbles, thin - Mount the drive shafts as described under the heading:
areas or gaps. ”525030 overhauling hubs”.
Any flaws must be corrected in as short a time as possible. - Apply LOCTITE 577 thread-locking oil on the oil drain
plug thread, screw it into the axle housing, tightening it
Avoid using too much material to seal the joint. to the required torque.
Too much sealant would tend to come out on both sides of - Add lubricating oil in the required quantity and grade
the joint. through the hole.
After applying the sealant, the joints need to be assembled - Apply LOCTITE 577 thread-locking oil on the inspection
immediately (10 - 20 minutes). plug thread, screw it into the axle housing, tightening it
To seal at a later date, there is product 21623 capable of to the required torque.
softening or liquefying the above-mentioned sealant. - Take the assembly off the stand.
It is essential to clean the surface to be sealed in order to
achieve good future sealing.
NOTE The assembly should be put back on its mounting

Figure 65 to prevent the dust guards and/or brake discs from
getting damaged.
108430
Mount the cover (1) and screw on the screws (2).

- Flanged screws (for solution without gasket).
- Screws with washer (for solution with gasket).

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DAILY EURO 4 REAR AXLE NDA RG 35
Rear axles NDA RG
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Air breather disassembly - assembly . . . . . . . . 48
- Replacing the wheel hub bearing . . . . . . . . . . 49
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- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

36 REAR AXLE NDA RG DAILY EURO 4
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DESCRIPTION The clearance between pinion and crown wheel is adjusted

using a hypoid crown wheel and pinion.
The gearing of the differential is composed of two planetary
pressed arms.
gears and two crown wheels.
The wheel hubs are keyed, with UNIT BEARINGS lubricated
for life, onto the arms of the axle housing.
The rolling torque of the bearings of the bevel pinion is
The bearings UNIT BEARINGS need no adjustment.
between the two tapered roller bearings. The brakes are disc brakes with floating brake calipers.
In addition, it is possible to adjust the position of the bevel The disc brakes are keyed onto the wheel hubs.
pinion with respect to the ring bevel gear by changing the
The brake calipers are secured with flanges fixed onto the
arms of the axle housing.
pinion rear bearing external ring.
Brake caliper is equipped with parking brake device.
The gear housing is supported by two tapered roller bearings.
The rolling torque of the bearings is adjusted with adjustment
rings between the spacer rings and the external rings of the
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bearings.
Figure 1
107857

Type of rear axle:

NDA RG
Simple reduction type with mech-
anical control differential locking
DIFFERENTIAL UNIT
1/4.182 (11/46) - 1/4.444 (9/40) - 1/4.889 (9/44)- 1/3.416

(12/41) - 1/3.916 (12/47) - 1/3.154 (13/41) - 1/3.615 (13/47) -
(No. of teeth: pinion/crown)
1/3.308 (13/43) - 1/3.727 (11/41)

(without seal ring) Nm 2.3 ÷ 3.3
kgm 0.23 ÷ 0.33
pinion bearings
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Bevel pinion bearings pre-load ad- 0.545 ÷ 1.070 mm
> justment rings with progression of 0.025 mm.
Temperature at assembly of inner
-
Position of bevel pinion with re-

By means of adjustment spacers
spect to differential casing

> placed between bevel pinion and
differential casing with progression of 0.025 mm.

torque
Nm 2.7 ÷ 3.9
kgm 0.27 ÷ 0.39

Thickness of adjustment rings of dif- 1.00 ÷ 1.95 mm

> ferential casing bearings rolling
torque with progression of 0.05 mm.
bevel gear
- 1/3,615 - 1/3,727 - 1/3,916 -
1/4,182 - 1/4,444: 0.13 ÷ 0.18
- 1/3,154 - 1/3,308 - 1/3,417 -
1/4,889: 0.15 ÷ 0.20

Type of rear axle:

NDA RG


0.05 ÷ 0.15 mm
crown wheels
WHEEL HUBS
Wheel hub bearings UNIT-BEARING
Wheel hub bearings end play --
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Nm --
kgm --
Adjustment of wheel hub bearings By means of nut

end play Torquing the securing nut

Quantity Litres 1.35
Max capacity (GAW) kg 2240

TIGHTENING TORQUES
Figure 2
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107858
NDA RG REAR AXLE DIFFERENTIAL SECTION
TORQUE
PART
Nm Kgm
1 M26x1.5 bevel pinion securing nut 400 ÷ 500 40.8 ÷ 51.0
2 M12x1.5 ring bevel gear wheelwork box securing screw 89 ÷ 108 9.0 ÷ 11.0
3 M22x1.5 oil filling plug** 49 ÷ 62 5.0 ÷ 6.32
4 Screw securing caps to differential box 100 ÷ 120 10.2 ÷ 12.2
5 M8x1.25 rear axle box rear cover securing screw 80 ÷ 95 8.2 ÷ 9.7
- M22x1.5 oil draining magnetic plug** 49 ÷ 62 5.0 ÷ 6.3
* Apply Loctite 5910 on the housing
** Apply Loctite 577 on the plug thread

Figure 3
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107859
NDA RG REAR AXLE DIFFERENTIAL SECTION

Figure 4
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108433
NDA RG REAR AXLE WHEEL HUB SECTION
TORQUE
PART
Nm kgm
1 Wheel securing screw -
2 M10x1.25 screw securing half shaft to wheel hub 63 ÷ 76 6.4 ÷ 7.7
3 M52x1.5 ring nut checking wheel hub bearing 545 ÷ 565 55.5 ÷ 57.6
4 M10x1.25 screw securing brake disk to wheel hub 69 ÷ 76 7.0 ÷ 7.7
5 M14x1.5 screw securing shoes support to caliper support 177 ÷ 217 18.0 ÷ 22.1
6 M10x1.5 screw securing brake caliper support to rear axle arm 85 ÷ 97 8.7 ÷ 9.8

TOOLS
99321024 Hydraulic trolley for removing and refitting wheels
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99322215 Driving and steering axle overhaul stand
99341001 Double effect bridge
99341003 Single-acting rear axle
99341005 Reaction bridge

TOOLS
99341009 Pair of retainers
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99341015 Clamp
99345057 Extractor reaction block
65 mm. diam. box wrench for disassembly - assembly wheel hub locking
99355087 ring

TOOLS
99370007 Grip for interchangeable punches
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Tool for measuring thickness of bevel pinion adjustment rings (to
99370239 be used with 99395728)
99370317 Lever and relevant extension bar to retain flanges
99370497 Tool for assembly of wheel hub
99370498 Tool for assembly of wheel hub bearing and phonic wheel

TOOLS
Axle universal support during removal/installation

99370617
99372236 Tool to move brake caliper piston back
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Keying tool for assembly of differential bevel pinion gasket (to be used
99374022 with 99370006)
Punch to fit external races of bearings

99374091 (diameter 55 ÷ 69 mm use with 99370007)
Punch to fit external races of bearings

99374092 (diameter 69 ÷ 91 mm use with 99370007)
99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment

TOOLS
Dial gauge with support to be used with the tools to determine the
99395728 adjustment thickness of the bevel pinion
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525010 OVERHAULING THE REAR AXLE 525030 Wheel hub overhaul

ASSEMBLYOVERHAULING THE
REAR AXLE ASSEMBLY Figure 7
NOTE For differential assembly repair operations, refer to
what described in chapter ” NDA-RS rear axle” on
pages 22 to 34.
NOTE The drive shafts, brake disc and calipers, air

breather and differential can all be removed and
refitted even with the unit mounted on the vehicle.

overhauling, drain oil by loosening rear axle casing plug.
108435
Figure 5 Take out the screws (1) and remove the brake caliper (2)
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with its brake linings from the mounting.

! dropped.
sharp metal tools.
Do not dirty or wet the rubber caps with mineral grease or
oil.
Do not dirty the pads with liquids or grease.
Do not operate the parking brake lever before mounting on
107860
the disc.
Set the entire rear axle assembly on stand 99322215. This makes the piston come out, decreasing the gap between
the two brake linings and jeopardizing wearability on the disc.
Should this be done unexpectedly, it is necessary to take
NOTE The identification data of the rear axle unit are down the brake linings and move the piston back with tool
given on the plate (1) fixed near to the leaf spring 99372236, taking the precautions given in the BRAKES
attachment support. section.
525013 Air breather disassembly - assembly

Figure 8
Figure 6
107854
101967
Take out the screws (1) and remove the brake caliper with
its brake linings from the mounting. Take out the screws (1) and remove the drive shaft (2).

Figure 9 Figure 11
44613
44616
Lift up the notch (⇒) of the ring nut (1). Using the wrench The bearing (1) is removed from the wheel hub with the aid
99355087 (2) remove the ring nut (1), take out the washer of an ordinary punch.
and extract the wheel hubs (3).
Assembly
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NOTE Bearing (1) driving load is 2100 ÷ 5000 kg.
NOTE In resting the hubs on the bench, pay attention that

phonic wheel is not being damaged.
Figure 12
525031 Replacing the wheel hub bearing

Disassembly
45164
The new bearing should be mounted in the wheel hub with

Figure 10 a press and tool 99370498.
Figure 13
101969
Remove bearing protection ring.

Take out the screws (2) and remove the brake disc (1) from 101970
the wheel hub. Check the brake disc as described under the
Brakes heading. Mount the brake disc (1) on the wheel hub (2) and tighten
the fixing screws (3) to the required torque.

Figure 14 Figure 16
44618
44621
If it is necessary to replace the pins of the wheel hub (1), Mount the inserter 99370497 (2) on the sleeve.
before mounting the new ones, check that the mating surface Lubricate the sleeve with TUTELA W90/M-DA oil and key
of the pin head is free from burrs, dross and blisters. the wheel hub (1).
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The pins should be driven in by applying a load on their head
no greater than 2000 kg.
After driving them home, check that the pins are perfectly in
touch with the hub: maximum orthogonal tolerance 0.2 mm.
Figure 15
44619
Stand the bearing of the wheel hub (2) on a special mounting

that permits rotation. With a magnetic dial gauge (1) check
the off-centring of the brake disc on both sides.
Centering error must not exceed 0.1 mm.

Figure 17 Figure 19
44626
Apply IVECO 1905685 sealant on the contact surfaces of the

44622 drive shaft (2) with the wheel hub (1).
Mount the drive shaft (2) in the sleeve.
Mount new washer (1), ring nut (2) and, using wrench Tighten the screws (3) securing the drive shaft (2) to the hub
99355087 (3), tighten ring nut (2) at prescribed torque. (1) to the required torque.
Notch the fixing ring nut (2) on the milling of the axle housing After the assembling operation has been completed, fill the
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arm.
rear axle case with TUTELA W90/M - DA oil to the
prescribed amount and grade.
Figure 18
108435
Mount brake caliper support on rear axle arm observing

prescribed tightening torques.
Thread braking gaskets.
Apply brake caliper (2) to the support and tighten securing
screws (1) at prescribed torque using a torque wrench.
Where brake caliper plunger must be withdrawn, observe
what indicated in section Brakes.
NOTE On each brake caliper remounting operation,

replace screws (1): these screws cannot be reused
once they have been unscrewed.

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DAILY EURO 4 REAR AXLE 450511 53
Rear axles 450511
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REAR AXLE REMOVAL - REFITTING . . . . . . . . 65
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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- Replacing the wheel hub bearing . . . . . . . . . . 68
DIFFERENTIAL REPAIR OPERATIONS . . . . . . . 71
- Disassembly of differential locking . . . . . . . . . . 71
- Assembling the differential locking device . . . . 71
- Differential locking removal . . . . . . . . . . . . . . . 71
- Differential locking refitting . . . . . . . . . . . . . . . 71
- Adjusting the differential locking device . . . . . 72
- Disassembling the differential unit . . . . . . . . . . 72
- Disassembly of gear housing . . . . . . . . . . . . . . 73
- Assembly of gear housing . . . . . . . . . . . . . . . . 75
- Assembling bevel pinion unit . . . . . . . . . . . . . . 75
- Differential unit refitting . . . . . . . . . . . . . . . . . 79

54 REAR AXLE 450511 DAILY EURO 4
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The gear housing is composed of two half-housings.
pressed arms.
It may be of two different sizes depending on the ratio of the
crown wheel and pinion.
The gearing of the differential is composed of four planetary
The rolling torque of the bearings of the bevel pinion is
between the two tapered roller bearings. The wheel hubs are keyed, with UNIT BEARINGS lubricated
for life, onto the arms of the axle housing.
In addition, it is possible to adjust the position of the bevel
pinion with respect to the ring bevel gear by changing the The bearings need no adjustment.
The brakes are disc brakes with floating brake calipers.
pinion rear bearing external ring.
The disc brakes are keyed onto the wheel hubs.
The brake calipers are secured with flanges fixed onto the
arms of the axle housing.
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bearings. The parking brake is the drum type, built into the brake disc.
Figure 1
51858


Type of rear axle:
450511
Electric control mechanical differential locking on request
DIFFERENTIAL UNIT 13/41(1/3.15)
( ) - 13/43(1/3.31)
( ) - 13/47(1/3.62)
( ) - 12/47(1/3.92)
( )-
11/46(1/4 18) - 9/40(1/4.40)
11/46(1/4.18) 9/40(1/4 40) 9/44(1/4.89)
9/44(1/4 89) - 9/46(1/5.11)
9/46(1/5 11) -
Reduction bevel gear pair ratio 9/47(1/5.22) - 8/45(1/5.63) - 7/41(1/5.86)
(No. of teeth: pinion/crown) 13/47(1/3.62) - 12/47(1/3.92) - 11/46(1/4.18) - 9/40(1/4.40) -
8/45(1/5.63) - 9/47(1/5.22)

(lubricated bearings and gaskets)
Nm 1.2 ÷ 2.4
New bearings
kgm 0.12 ÷ 0.24
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pinion bearings
> Bevel pinion bearing preload 1 ÷ 1.975 mm

adjusting ring thickness with progression of 0.025 mm.
Temperature of assembly of inner

80 °C ÷ 90 °C
Position of bevel pinion with

respect to differential casing
Thickness of adjusting ring placed 1 ÷ 1.975 mm

> between bevel pinion bearing and
differential carrier. with progression of 0.025 mm.

torque
Nm 2 ÷ 2.8
kgm 0.20 ÷ 0.28

Differential carrier bearing rolling 1 ÷ 1.95 mm

> torque adjusting ring thickness with progression of 0.05 mm.

0.15 ÷ 0.20 mm
bevel gear


0.12 ÷ 0.18 mm
crown wheels

Type of rear axle:

450511
WHEEL HUBS
Wheel hub bearings Unit-Bearing
Wheel hub bearings end play -

Nm -
kgm -
Adjustment of wheel hub bearings Non-adjustable

end play Tightening to fixing ring nut torque
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Quantity Litres 1.9
Dry rear axle weight :
- With ABS kg 154,6
- Without ABS kgg 153
- Max capacity (GRW) kg 3700

TIGHTENING TORQUES
Figure 2
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44588
REAR AXLE DIFFERENTIAL SECTION WITH DIFFERENTIAL LOCKING
TORQUE
PART
Nm kgm
1 M26x1.5 bevel pinion securing nut. 400 ÷ 500 40 ÷ 50
2 Screw securing half-housing and ring bevel gear M14 x 1.5 200 ÷ 210 20 ÷ 21
3 Screw securing mounting for differential locking to the axle housing or securing cover 21 ÷ 25 2.1 ÷ 2.5
for differential locking mounting seat cover
4 Screw securing gearing inspection cover to the axle housing 21 ÷ 26 2.1 ÷ 2.6
5 Screw securing caps to axle housing 96 ÷ 117 9.6 ÷ 11.7

Figure 3
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51862
450511 REAR AXLE DIFFERENTIAL SECTION

Figure 4
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87907
WHEEL HUB SECTION
TORQUE
PART
Nm kgm
1 Wheel retaining nut M18 290 ÷ 349 29 ÷ 34.9
2 Screw securing drive shaft to the wheel hub M10x1.25 63 ÷ 76 6.3 ÷ 7.6
3 Ring nut retaining wheel hub bearing M52x1.5 545 ÷ 565 54.5 ÷ 56.5
4 Screw securing brake disc to wheel hub M10x1.25 69 ÷ 76 6.9 ÷ 7.6
5 Screw securing caliper mounting to shoe mounting M14x1.5 180 ÷ 220 18 ÷ 22
6 Screw securing shoe mounting to axle housing M10x1.5 85 ÷ 97 8.5 ÷ 9.7
7 Screw securing guard 8 0.8
** Screw securing sensor mounting 5÷7 0.5 ÷ 0.7
* Spread the surface of the drive shaft - wheel hub union with B-type sealant.
** When assembling the screws securing the timing sensor mounting, apply a few drops of LOCTITE 243 thread-lock onto
the thread of the corresponding holes of the bracket welded onto the axle arm.

TOOLS
99321024 Hydraulic trolley for removing and refitting wheels
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99322215 Driving and steering axle overhaul stand
99341001 Double effect bridge
99341005 Reaction bridge

TOOLS
99345056 Counter block for pullers
99348001 Extractor with locking device
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65 mm. diam. box wrench for disassembly - assembly wheel hub locking
99355087 ring
Tool for measuring thickness of bevel pinion adjustment rings (to be

99370309 used with 99395728)

TOOLS
99370317 Lever and relevant extension bar to retain flanges
99370497 Tool for assembly of wheel hub
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99370498 Tool for assembly of wheel hub bearing and phonic wheel
99370617 Axle universal support during removal/installation
Keying tool for assembly of differential bevel pinion gasket (to be used
99374022 with 99370006)

99374092 with 99370007)

TOOLS
99389819 Torque wrench (0 to 10 mm) with 1/4” square attachment
Dial gauge with support to be used with the tools to determine the
99395728 adjustment thickness of the bevel pinion
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REAR AXLE REMOVAL - REFITTING

Removal Figure 5
Position the vehicle on level ground and lock the front wheels.
Loosen the nuts securing the rear wheels.
Lift the vehicle at the back and set it on stands.
Put the hydraulic trolley 99321024 under the rear wheels. Take out
the nuts securing the wheels.
Unscrew the handbrake adjustment nut (4). Free the cables from the
vehicle crosspiece, unhooking the retaining clamps (3).
Unscrew the screws (6) securing the propeller shaft.
Disconnect the electric cables for indicating brake lining wear (2) and
(13), for the ABS speed sensors, if present.
Disconnect the braking corrector adjustment tie (14) from the axle
housing.
Unscrew the nuts (5) securing the shock absorbers.
Disconnect the oil pipe (1) from the fitting secured to the axle
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housing.
Unscrew the screws (9) securing the stabilizer bar (10) to the axle.
Disconnect the pipe (16) from the axle housing oil vapour vent.
For axles with differential locking only
Release spring (17) and unthread flexible tie rod (18) from bracket
(19).
Disconnect the electric cable of the differential locking indicator
transmitter (15).
For all vehicles
Position a hydraulic jack equipped with the mounting 99370617
under the axle.
Unscrew the nuts (7) of the brackets (8) securing the axle to the leaf
spring (11).
Lower the hydraulic jack and extract the axle.
Refitting
reverse order, observing the required tightening torques for the
screws and/or nuts.
At procedure completion:
- Check the thread of the brackets joining the leaf springs to the
axle. If there are any irregularities, rectify the thread (operation
500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described under
the relevant heading (operation 784010).
- Check for self-locking nuts having been replaced;
- Check the state of the flexible pads (12) and replace them if they
have deteriorated (operation 500417).
- Check for rear axle box lubrication oil correct level. 52121

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525010 OVERHAULING THE REAR AXLE Figure 8

ASSEMBLY
Figure 6
44611
Unthread braking pads (1). Take off screws (→) and detach
support (2).
44609
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Set the entire rear axle assembly on stand 99322215.
Figure 9
The identification data of the rear axle unit are given

! on the plate (1) fixed near to the leaf spring
attachment support.
525030 Wheel hub overhaul

Figure 7
44612
Take out the screws (⇒) and remove the drive shaft (1).
Figure 10
101965
Disconnect the pipe (2) from the support bracket (1).

Remove caps (3), take off screws (4), then remove brake
caliper (5) from support (6).
44613
NOTE The thread of the screws securing the brake caliper

is treated with adhesive. Therefore, they must not Lift up the notch (⇒) of the ring nut (1). Using the wrench
be reused, but replaced with new ones every time 99355087 (2) remove the ring nut (1), take out the washer
they are removed. and extract the wheel hubs (3).

525031 Replacing the wheel hub bearing Figure 14
Figure 11
45164
44614 The new bearing should be mounted in the wheel hub with
If the hub is fitted with a phonic wheel (2), take it out with a press and tool 99370498.
the extractor (1) 99341001 as shown in the figure.
Otherwise, take out the bearing guard ring. Figure 15
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Figure 12
44617
Mount the brake disc (1) on the wheel hub (2) and tighten
44615 the fixing screws (⇒) to the required torque.
Take out the screws (⇒) and remove the brake disc (1) from
the wheel hub. Check the brake disc as described under the Figure 16
Brakes heading.
Figure 13
44618
44616
If it is necessary to replace the pins of the wheel hub (1),
The bearing (1) is removed from the wheel hub with the aid before mounting the new ones, check that the mating surface
of an ordinary punch. of the pin head is free from burrs, dross and blisters.
no greater than 2000 kg.
NOTE Bearing (1) driving load is 2100 ÷ 5000 kg. touch with the hub: maximum orthogonal tolerance 0.2 mm.

Figure 17 Figure 20
44619
Stand the bearing of the wheel hub (2) on a special mounting

that permits rotation. With a magnetic dial gauge (1) check
44621
the off-centring of the brake disc on both sides.
Off-centring must not exceed 0.1 mm.
NOTE Check and, if necessary, adjust the clearance
between the parking brake drum and shoes as
Figure 18
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described in the Brakes section.
Mount the inserter 99370497 (2) on the sleeve.

Lubricate the sleeve with TUTELA W140/M-DA oil and key
1 the wheel hub (1).
45165
The phonic wheel (2) should be mounted in the hub with the
punch 99370498 (1), checking after assembly that the
”phonic” wheel rests perfectly in its seat in the hub.
Figure 21
Figure 19
44622
44620
Check the orthogonality of the phonic wheel (2), proceeding

as follows:
Position the feeler of the magnetic dial gauge (1) on the
phonic wheel. Mount the washer (1) and a new ring nut (2). Using the
wrench 99355087 (3), tighten the ring nut (2) to the required
Making the wheel hub (3) turn, check that the maximum torque.
error of orthogonality of the phonic wheel (2) is no greater Notch the fixing ring nut (2) on the milling of the axle housing
than 0.1 mm. arm.

Figure 22 Having to move the brake caliper piston back, keep to the
instructions given in the BRAKES section.
Mount only new screws (1, Figure 24).

! Every time they are removed, they must be replaced.
Figure 25
44623
Mount the support (2) and tighten the fixing screws (1) to
the required torque.
Figure 23
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101962
Fit new protection caps (3).

Connect the pipe (2) to the support bracket (1).
44611
Mount braking pads (1).
Braking pad with wear signalling unit must be

! mounted at brake caliper plunger side.
Figure 26
Figure 24
44626
Apply IVECO 1905685 sealant on the contact surfaces of the

101971 drive shaft (2) with the wheel hub (1).
Mount the drive shaft (2) in the sleeve.
Fit brake caliper (3) to support (2), then use torque wrench
(4) to tighten fastening screws (1) to a torque of 32 to 36 Tighten the screws (3) securing the drive shaft (2) to the hub
Nm. (1) to the required torque.

526210 DIFFERENTIAL REPAIR Assembling the differential locking device

OPERATIONS
Assemble the differential locking device by following the
526260 Disassembly of differential locking removal operations in the reverse order.
Re-attach the differential locking device to the rear axle
Figure 27 casing as follows:
Differential locking refitting

Figure 29
61869
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Remove the spring (1).
Unscrew and remove the 4 screws (2) including washers and
then disconnect the differential locking device (3).
If required, remove the unit as described in the following
paragraphs.
61869
Mount a new O-ring on the differential locking attachment

plane.
Position the previously assembled support (3) so as to insert
the control lever in the spline on the sliding sleeve.
Insert the 4 screws (2) complete with washers and spring
washers and tighten the screws to the driving torque of 23
Nm (2.35 kgm).
Assemble the spring (1).
Adjust the differential locking device by following the
procedures below.
Differential locking removal
Figure 28
23227
Remove gasket (4).

By means of a normal beater knock out the elastic pin (2),
remove the lever (1) complete with ring and washer.
Finally, remove the control lever (3) from the support (5).

Figure 30
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107982
DIFFERENTIAL LOCKING DEVICE COMPONENTS

1. Flexible tie rod bracket (Bowden) - 2. Rear axle casing - 3. Spring - 4. Gasket - 5. Sealing ring - 6. Gasket - 7. Sleeve
control lever (9) - 8. Elastic pin to fix lever (7) to lever (12) - 9. Differential locking sliding sleeve - 10. Spring coupling
plate (11) - 11. Lever return spring (12) - 12. Transmission lever - 13. Adjusting screw nut - 14. Adjusting screw -
15. Differential locking device body.
Adjusting the differential locking device Figure 31
Engage the sliding sleeve (9). Once this has been done,
loosen the nut (13), move the adjustment screw (14) so that
it is contact with the control lever (7). After this, unscrew the
adjustment screw by 9.5 turns (corresponding to 9.5 mm.
travel of the screw) and lock it with the fastening nut (13).
Disassembling the differential unit
NOTE Before carrying out repair operations on the

differential unit you must drain off the oil and 18216
disassemble the drive shafts. For the rear axle, you
must disassemble the differential locking as Unscrew the screws (1) complete with tab washers and
described in the relevant paragraphs. spring washers and remove the gear housing inspection
cover (2) complete with gasket.

Figure 32 Disassembly of gear housing

Figure 34
44600
44598
Extract the support bearing inner rings (3 and 5) and shoulder
Mark the position of the caps (1 and 2) and remove them. ring (2) from the gear housing and, by means of the puller tool
99348001 (4), extract the counter block (1).
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NOTE The thrust ring (2) is only present with rear axles
fitted with differential locking.
Figure 35
18222
Figure 33
NOTE Mark the cover (1) and the gear housing (4).
Unscrew the screws (2), remove the ring bevel gear (3) and
the gear housing (4) cover (1).
Figure 36
44599a
Take out the gear housing (1).

Note the assembly position of the adjustment rings (3) and
take them out of the housing together with the spacer rings
(2). 62099
NOTE In the case of reuse, do not swap over the assembly Remove the crown wheel (2) on the cover side with its thrust
positions of the external rings (4) of the tapered washer (3) from the gear housing (1).
roller bearings. Using a generic beater to remove the long pin (4) and the
two short pins (5) from the gearing case (1).

Figure 37 Figure 38
20378 18226
Remove the crown wheel (1) on the gear housing side with
Remove the spider (1) and the four planetary gears (2) with
the thrust washers.
their shoulder washers (3) from the gear housing.
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Figure 39
51863
PARTS COMPRISING THE DIFFERENTIAL UNIT

1. Nut - 2. Transmission connection coupling - 3. Seal - 4. Front bearing - 5. Pinion shim ring - 6. Fixed
spacer - 7. Spacer ring - 8. Adjustment ring - 9. Rear bearing - 10. Bevel pinion - 11. Ring bevel gear - 12. Fixed ring -
13. Adjustment ring - 14. Bearing - 15. Thrust ring (axle with differential locking) - 16. Gear housing - 17. Crown wheel
thrust washer - 18. Spider - 19. Crown wheel - 20. Gear housing cover - 21. Screw - 22. Planetary gear thrust washer - 23.
Planetary gear - 24. Short pin - 25. Long pin.

Assembly of gear housing Figure 43

Figure 40
18237
18226 Assemble the cover and make the marks made during
disassembly coincide. Assemble the ring bevel gear and fasten
Position the crown wheel (1), gear housing side, complete this to the half-casing by means of the fixing screws.
with thrust washer, into its own housing. By means of a torque wrench (1) tighten the fixing screws (2)
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to the required tightening torque.
Figure 41 Figure 44
18240
Only for axles with differential lock.

20379 Using tool 99305121, heat thrust ring (1) to a temperature
Position the two planetary gears (1) complete with thrust of 120ºC ÷ 150ºC for 15’ and fit on the gear casing (2) from
washers, spider (2) and then insert the long pin (3). the side with the differential lock.
Figure 42
Assembling bevel pinion unit
Figure 45
20380
Position the other two planetary gears (1) complete with 18241
thrust washers and then insert the two short pins (2).
Rotate the planetary gears-crown wheel unit and check that
it is free without stiffness. On a surface plate (2) zero the dial gauge (1) placed on the
Assemble the other crown wheel complete with thrust support 99395728 (3) and lightly pre-load it.
washer.

Figure 46 Figure 48
101977 51840
Fit tapered-roller bearing internal ring (2) onto false pinion Fit the mounting 99395728 (2) with the dial gauge (1) on the
99370309 (1) with the washer supplied (3). dummy pinion 99370309 (3).
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Orientate the, previously zeroed, dial gauge so as to position
the rod on the lowest portion of the seat of the bearing
Figure 47 supporting the gear housing and note the difference A1.
Repeat the same operation on the seat of the other bearing

and note the difference A2.
Thickness S to be added to adjusting ring thickness (4,

Figure 50) used for measuring, for pinion positioning is
obtained by the following formula:
S = A1 + A2 − ( B)
2
A1 indicates the value measured on the right-hand seat.
A2 indicates the value measured on the left-hand seat.
B indicates the value marked on the bevel pinion (see
51839
Figure 49).
Position the dummy pinion 99370309 (1), assembled as For example:
shown in Figure 46, on the external ring (2) of the tapered
roller bearing.
On the opposite side, fit the taper bearing internal ring (3)
S = 1, 05 + 1, 10 − (− 0, 05) = 2, 15 + 0, 05 = 1,125
on the dummy pinion (1) and the transmission shaft flange
(4) . 2 2
Screw on the nut (5) so that the dummy pinion turns freely
with no end float.
The result of the formula must be added algebraically to the
value of the adjusting ring used to make the measurements.
Example:
if the value of the adjusting ring used is 3.00 mm, replace with
one measuring 4.125 mm (3.00 + 1.125).

Figure 49 Figure 51
18251
18246
Using a suitable punch (1) and a hydraulic press, mount the
internal ring (2) of the tapered roller bearing on the bevel
pinion (3).
NOTE If the value marked on the pinion is preceded by a
positive sign (+), it must be subtracted from the
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Figure 52
value of the sum divided by two for both seats,
whereas it has to be added if it is preceded by a
negative sign (-).
Unscrew the retaining nut, the transmission connection

flange and remove it and the bearing from the dummy pinion.
Remove the dummy pinion with the mounting 99395728,
dial gauge and rear bearing from the axle housing.
18252
Figure 50 Position the fixed spacer (3) and the adjustment ring (2), used
previously to obtain the required rolling torque, on the bevel
pinion (1).
Figure 53
51838
If required, replace adjusting ring (4) with a new one having

the calculated thickness, after removing bearing outer ring (3) 62097
from rear axle casing (5) by beater. Position the axle casing as indicated in the figure.
Then fit the new adjusting ring (4) into rear axle casing (5). Fit the taper bearing internal ring (1) and the transmission
shaft flange (2).
Using the punch 99374092 (2) and grip 99370007 (1), mount Position a suitable pipe (3) on the stand so that the flange (2)
the external ring (3) of the tapered roller bearing. and the taper bearing internal ring (1) are correctly
supported.

Figure 54 Figure 56
74728
51845
Mount the bevel pinion (1) in the axle housing so as to enter Using torque meter 99389819 (1), detect bevel pinion rolling
the internal ring (2) of the tapered roller bearing. torque.
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Tap on the end of the pinion (1) so that the transmission shaft NOTE The rolling torque must be measured at an ambient
flange retaining nut (3) can be fitted. temperature of 25°C, making the pinion turn at a
speed of 50 rpm after it has made 10 turns.
If the reading differs from the prescribed value, disassemble

the pinion (1, Figure 54), replace the adjuster ring (2,
Figure 52) with a ring of the correct thickness.
Figure 55
51846
Use tool 99370317 (2) to prevent the flange (1) from

rotating.
Tighten the bevel pinion retainer nut to the required torque
with a torque wrench (3).

Differential unit refitting

Figure 59
Figure 57
107983 18252
Using a suitable punch, with a grip, drive the external ring (4) Heat the internal ring (4) of the tapered roller bearing to
for the front bearing into the axle housing (1). 80°C ÷ 90°C for approximately 15 min. and drive it, with a
suitable punch, onto the bevel pinion (1).
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Position stop ring (5) with 2 mm thickness and drive outer
ring (3) of rear bearing using a proper beater. Position the spacer ring (3) and adjustment ring (2),
Determine bevel pinion position adjusting shim as described calculated beforehand to obtain the required rolling torque,
above. on the bevel pinion (1).
Remove the external ring (3) of the tapered roller bearing.

Position adjusting ring (2) having the calculated thickness, on
stop ring (5).
Refit the external ring (3) of the tapered roller bearing.
Figure 58
Figure 60
51865
Lubricate the internal ring of the front bearing and position

it in the housing.
Using the key 99374022 (1) and grip 99370006 (2), mount
the pre-lubricated seal.
Determine bevel pinion rolling torque adjusting ring as
described above. 51866
Position the axle housing as shown in the figure.

NOTE The rolling torque of the bevel pinion must be On the stand, set a pipe (3) of such diameter and length as
measured with lubricated bearings and seals. to provide a solid supporting surface for the flange (2) and
the internal ring (1) of the front bearing above, already
mounted in the axle housing.

Figure 61 Figure 63
20384
4
Position the sliding sleeve in the rear axle housing for
51867
differential locking (if present). Mount the external rings (1)
Insert the bevel pinion (1), assembled as shown in the figure, for the gear housing support bearings and then position the
in the internal ring of the front bearing (2) and in the flange previously mounted gear housing in the rear axle housing.
(3).
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NOTE Strike the top of the bevel pinion until it is possible Figure 64
to fit the nut (1, Figure 62) securing the flange (3).
Take out the support pipe (4).
Complete assembling the pinion by fully tightening
the nut.
Block rotation of the transmission flange with the retainer

tool 99370317.
Using a suitable Allen wrench and the torque wrench, tighten
the bevel pinion retainer nut (1, Figure 62) to the required
torque.
To be on the safe side, check the rolling torque of the bevel 44594
pinion with the dynamometer 99389819.
Mount the spacers and adjustment rings in the same number,
thickness and position found during disassembly, in the
following order: spacer (1), adjustment ring (2), adjustment
ring (3) and spacer (4).
Figure 62
* DIRECTION OF ROTATION
OF THE NUT
51868
Make a cut in the collar of the nut (1) by the milling of the
bevel pinion (2) as shown in the figure.

Figure 65
18262
Complete mounting operation by checking total rolling

torque and the clearance of ring gear and pinion coupling as
described for NDA rear axles.
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Position a new seal ring over the gear housing inspection
attachment surface.
Mount the cover (3), insert the fixing screws (2) complete
with tab washers and spring washers.
Tighten the screws (2) with the torque wrench (1) to the
required tightening torque.
NOTE Do not tighten the screws to a torque greater than

the value indicated since this would impair the
sealing effect of the gasket placed between the
coupling plane and the gear housing inspection
cover.
Mount the differential locking device (if present) and adjust

it as described under the relevant heading.
Mount the drive shafts as described under heading: “525030
Overhauling the Hubs”.
Screw on the oil drainage plug and tighten it to the required
torque.
Add lubricating oil in the required quantity and grade through
the hole.
Screw on the oil filler plug and tighten it to the required
torque.
Take the assembly off the stand.
NOTE The assembly should be put back on its mounting

to prevent the dust guards and/or brake discs from
getting damaged.

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DAILY EURO 4 REAR AXLE 450517/2 83
Rear axle 450517/2
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CHARACTERISTICS AND DATA . . . . . . . . . . . 86
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REAR AXLE REMOVAL - REFITTING . . . . . . . . 95
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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- Air breather disassembly - assembly . . . . . . . . . 97
- Overhaul of wheel hubs . . . . . . . . . . . . . . . . . 97
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
- Stud replacement . . . . . . . . . . . . . . . . . . . . . . 99
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
DIFFERENTIAL REPAIR OPERATIONS . . . . . . . 102
- Differential locking . . . . . . . . . . . . . . . . . . . . . . 102
- Differential unit removal . . . . . . . . . . . . . . . . . 103
- Gearing case removal . . . . . . . . . . . . . . . . . . . 103
- Differential components check . . . . . . . . . . . . 105
- Rear axle casing check . . . . . . . . . . . . . . . . . . . 105
- Gearing case refitting . . . . . . . . . . . . . . . . . . . . 105
- Differential unit refitting . . . . . . . . . . . . . . . . . . 109

84 REAR AXLE 450517/2 DAILY EURO 4
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The gear housing is composed of two half-housings.
pressed arms.
It may be of two different sizes depending on the ratio of the
The central portion, seat of the differential unit, is equipped
crown wheel and pinion.
with cooling fins.
The gearing of the differential is composed of four planetary
Wheel hubs are supported by two ”SET RIGHT” type bear-
The rolling torque of the bearings of the bevel pinion is ad-
ings set on the sleeve.
justed by changing the thickness of the adjustment ring be-
tween the two tapered roller bearings. The bearings need no adjustment.
In addition, it is possible to adjust the position of the bevel pin- The brakes are disc brakes with floating brake calipers.
ion with respect to the ring bevel gear by changing the thick-
The disc brakes are keyed onto the wheel hubs.
ness of the ring between the axle housing and the bevel pinion
rear bearing external ring. Perrot type brake callipers are supported by flanges welded
to rear axle casing arms.
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The parking brake is the drum type, built into the brake disc.
bearings.
Figure 1
62983

CHARACTERISTICS AND DATA
Type of rear axle:

Bearing with single reduction and 450517/2
mechanical control differential
locking
DIFFERENTIAL UNIT

1/3,91 (11/43) - 1/4,30 (10/43) -
(tooth no.: pinion/crown wheel), on
1/4,56 (9/41) - 1/5,13 (8/41)
request
Bevel pinion bearing rolling torque

(lubricated gaskets and bearings)
Nm 2÷3
New bearings
kgm 0.20 ÷ 0.30
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Bevel pinion bearing preload
through adjustment rings
adjustment
> Bevel pinion bearing preload 1 - 2 mm

adjustment ring thickness with 0.025 mm progression
Temperature for fitting inner

80 °C ÷ 90 °C
Bevel pinion position with reference

By means of shims
to differential casing

> between bevel pinion and
differential casing with 0.025 mm progression
Bearings for gearing case 2 taper rollers
Differential case bearing rolling

torque
Nm 2.6 ÷ 3.9
kgm 0.26 ÷ 0.39
Adjustment of differential case

Through adjustment rings
bearing rolling torque
Thickness of adjustment rings for 2.65 ÷ 3.20 mm

> differential case bearing rolling
torque with 0.05 mm progression
Backlash between pinion and crown

0.15 ÷ 0.20 mm
wheel
Adjustment of backlash between

Through adjustment rings
pinion and crown wheel

Type of rear axle: 450517/2
WHEEL HUBS
Wheel hub bearings Two ”SET-RIGHT” type taper rollers
Hub bearing end play 0.16 max.
Wheel hub bearing rolling torque

Nm 0÷4
kgm 0 ÷ 0.4
Adjustment of wheel hub bearings

Fastening nut tightening to torque
end play
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Rear axle oil Tutela W140/M-DA (SAE 85 W140)
Amount Litres 3
kg 2.7
Max. capacity GAW kg 5000

TIGHTENING TORQUES
Figure 2
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62879
450517/2 (R0537) REAR AXLE DIFFERENTIAL SECTION
TORQUE
PART
Nm kgm
1 Bevel pinion retaining nut 533 ÷ 589 53.3 ÷ 58.9
2 Screw fastening gearing inspection cover to rear axle casing* 26 ÷ 21 2.6 ÷ 2.1
Screw fastening crown gear to 12RDAC5 half casing* 309,5 ÷ 342,5 30.9 ÷ 34.2
3
Screw fastening crown gear to 10RDAC5 half casing 266 ÷ 294 26.6 ÷ 29.4
4 Screw fastening half casings 61 ÷ 74 6.1 ÷ 7.4
5 Screw fastening differential locking device or cover 23 2,3
6 Screw fastening caps to rear axle casing 102 ÷ 113 10.2 ÷ 11.3
* Before tightening the screws, smear their threaded holes with IVECO sealant 1905683.

Figure 3
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74729
Figure 4
62878
ABS VERSION
TORQUE
PART
Nm kgm
1 Wheel fastening nut 238.8 ÷ 342.6 23.8 ÷ 34.2
2** Screw fastening axle shaft to wheel hub 56 ÷ 69 5.6 ÷ 6.9
3 Wheel hub bearing retaining ring nut 441 ÷ 540 44.1 ÷ 54
4 Safety screw 9.5 ÷ 11.5 0.9 ÷ 1.1
5 Screw fastening brake disc to wheel hub 54 ÷ 59 5.4 ÷ 5.9
6 Screw fastening brake calliper to rear axle 176 ÷ 194 17.9 ÷ 19.7
7 Screw fastening brake shoe support to rear axle casing 68 ÷ 75 6.9 ÷ 7.6
8*** Rpm sensor support fastening screw 5÷7 0.5 ÷ 0.7
* Apply IVECO 1905685 sealant on half shaft - wheel hub joint surface
** Apply IVECO 1905683 sealant on the threading of plugging screws
*** Apply LOCTITE 243 on the threading of holes

TOOLS
99305121 Hot air operated equipment
99306004 300 kg hydraulic crane
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99306010 Equipment for bleeding air from brake and clutch system
99321024 Hydraulic truck for removing - refitting wheels
99322215 Stand to overhaul axles
99345056 Counter block for pullers

TOOLS
99348001 Puller with locking device
99357080 Wrench (91.5 mm) for wheel hub bearing adjustment nut
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99370006 Handle for interchangeable beaters
99370007 Handle for interchangeable beaters
Tool to find bevel pinion shims (to be used with 99395728)

99370296
99370317 Counter lever and relevant extension to retain flanges

TOOLS
99370617 Universal support to hold axles during removal/refitting
Beater to fit in place bearing outer races (91-134) (to be used with
99374093 99370007)
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Element to fit in place wheel hub internal gasket (to be used with
99374132 99370006)
99374201 Element to fit in place differential bevel pinion gasket
99389819 Dynamometric wrench (0-10 Nm) connection 1/4”
Tool to check hub rolling torque (to be used with dynamometric

99395026 wrench)

TOOLS
99395684 Dial gauge with magnetic base
Dial gauge with support to be used with the tools for finding proper
99395728 bevel pinion shims
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REAR AXLE REMOVAL - REFITTING

Removal Figure 5
Position the vehicle on level ground and lock the front
wheels.
Loosen rear wheel fastening nuts.
Lift the rear part of the vehicle and position it on proper
stands.
Fit hydraulic truck 99321024 under the rear wheels, remove
wheel fastening nuts and then remove wheels.
Loosen handbrake lever adjustment nut (4). Release cables
(2) from vehicle cross member by releasing the retaining clips
(5), and from the side member brackets by loosening clamp
fastening screws (3).
Loosen propeller shaft fastening screws (6).
Release cables from clamps and disconnect the brake lining
(1) and (7) wear indication electrical cables of ABS sensors,
if any.
Loosen shock absorber (14) fastening nuts (16).
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Loosen the screws (17) fastening the stabilizer bar (10) to the
rear axle.
Disconnect brake oil pipes from connection (13) and secure
them to the chassis to prevent oil draining from system.
Disconnect pipe (15) from rear axle casing oil vapour bleed.
Position the hydraulic jack fitted with support 99370617
under the rear axle.
Loosen the nuts (8) of the brackets (9) fastening the rear axle
to the leaf spring (10).
Lower the hydraulic jack and remove the rear axle.
Refitting
reverse order, observing the required tightening torques for the
screws and/or nuts.
Afterwards, check that:
- Check the thread of the brackets joining the leaf springs to the
axle. If there are any irregularities, rectify the thread (operation
500412) or replace the brackets.
- Bleed the air from the brake hydraulic system as described under
the relevant heading (operation 784010).
- The self-locking nuts must not be reused.
- Check the state of the flexible pads (12) and replace them if they
have deteriorated (operation 500417).
- The lubricating oil in the axle housing should be at the right level. 61988

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525010 OVERHAUL OF REAR AXLE 525013 Air breather disassembly - assembly

Figure 8
The drive shafts, brake disc and calipers, air breather

! and differential can all be removed and refitted even
with the unit mounted on the vehicle.
Figure 6
62882
Take out the screws (1) and remove the brake caliper with its
brake linings from the mounting.
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525030 Overhaul of wheel hubs
62880 Disassembly
overhauling, drain oil by loosening rear axle casing plug. Dis- Figure 9
connect brake fluid pipes (2) from brake callipers (1) and from
rear axle casing and pipes (3) from rear axle casing.
Figure 7
62883
Take out the screws (1) and remove the brake caliper (2) with
its brake linings from the mounting.

! dropped.
62881
Set the entire rear axle assembly on stand 99322215. sharp metal tools.
Do not dirty or wet the rubber caps with mineral
grease or oil.
NOTE The identification data of the rear axle unit are given
on the plate (1) fixed near to the leaf spring attach- Do not dirty the pads with liquids or grease.
ment support. Check proper brake calliper and brake lining
conditions as described in ”Brake” section.

Figure 10 Figure 13
62889
62892
Rotate the wheel hub (1) to set downward one of the two
screws (2) located between hub reliefs; remove the screws Loosen bearing retaining ring nut (2, Figure 12) using wrench
and drain oil completely from wheel side. Remove the other 99357080 (1).
screws fastening the axle shaft (3) to the wheel hub (1).
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Figure 14
Figure 11
62893
62890 Remove the safety washer (1).
Remove the axle shaft (2) from the wheel hub (1).
Figure 15
Figure 12
62891 62894
Remove ring nut (1) safety screw (2). Sling brake disk (1) with rope and hoist, take off wheel hub (2)
complete with brake disk (1), front (3) and rear bearings, seal
ring and spacer.

Stud replacement
Figure 16 Figure 19
62884
62887
Remove front bearing (1) inner ring and spacer (2).
Remove screws (4) and disconnect the brake disc (5) from the Where the studs of wheel hub (1) must be replaced, before
wheel hub (3). mounting the new studs, make sure that studs head rest plane
is free from slag, burr and blisters.
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NOTE Check the brake disc as described in the ”Brake” no greater than 2000 kg.
section.
touch with the hub: maximum orthogonal tolerance 0.2 mm.
Figure 17
Figure 20
62885
Remove phonic wheel (1), if any, using suitable equipment.

Remove sealing ring (2) and the rear bearing inner ring (4) set
below from the wheel hub (3).
Figure 18
62888
Use handle 99370007 (1) and beater 99374093 (2) to fit

taper roller bearing outer rings into the wheel hub.
32445
NOTE This operation shall be performed using a press until
Use a suitable punch to remove the rear taper roller bearing positioning the rings at 5 mm from their abutting
outer ring (1). Repeat this operation to remove the front end, their fitting shall be then completed by hand.
taper roller bearing outer ring.

Figure 21 Figure 23
62932
62938
Lubricate rear taper roller bearing inner ring (4) with SAE W
140 M-DA oil and fit it to wheel hub (5).
Use tool 99374132 (2) provided with proper handle NOTE Check and, if necessary, adjust the clearance
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99370006 (1) to fit sealing ring (3). between the parking brake drum and shoes as
described in the Brakes section.
NOTE Use tool 99374132 (2) side to position the sealing

ring (3) at 1.5 mm from wheel hub side surface. Lubricate the sleeve and the sealing ring supporting ring (1)
with TUTELA W140/M-DA (SAE 85W140) oil.
Fit the phonic wheel, if any, on the wheel hub.
NOTE Phonic wheel fitting shall be performed after heating

it at 150ºC.
When fitting is over, check whether the phonic
wheel is resting perfectly on the hub seat. Figure 24
Check whether phonic wheel squareness and
oscillation is lower than 0.2 mm.
Figure 22
62897
Use suitable rope and hoist to fit wheel hub (1) on sleeve (4).
Lubricate spacer (2) and outer bearing inner ring (3) with
Tutela W140/M-DA and fit them on sleeve (4).
62896
Fit the brake disc (3) on the wheel hub (1) and tighten the
fastening screws (2) to the specified torque.

Figure 25 Figure 28
62891
62898 After checking the end play and the rolling torque, check
whether one of the adjustment nut (1) holes is coinciding with
Fit the safety washer (3) so that the clip is guided properly into one of the safety washer holes otherwise loosen the
rear axle casing sleeve groove. adjustment nut (1) until it is possible to fit the fastening screw
Tighten ring nut (4) with wrench 99357080 (1) and (2). Tighten the fastening screw (2) and the adjustment nut to
dynamometric wrench (2), tighten the new ring nut (4) to the
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the specified torque.
specified torque.
Figure 29
Figure 26
62902
Smear the contact surface between axle shaft (3) and wheel
hub (1) with IVECO sealing compound 1905685.
62899 Fit axle shaft (3), tighten the fastening screws (2), excluding
those set between the two wheel hub marks (see Figure 30)
Position the dial gauge 99395684 (1) with a magnetic base with tool 99370317 (4) lock wheel hub (1) rotation.
on the wheel hub (3) and rest the rod on the sleeve (2).
Check whether wheel hub end play is falling between 0 and Figure 30
0.16 mm.
Figure 27
62903
Set horizontally to ground the two holes (1) located between

62900 the wheel hub marks and pour through 0.2 l of W140 M-DA
Use tool 99395026 (2) and the dynamometric wrench oil on each wheel side.
99389819 (1) to check whether the wheel hub rolling torque Smear the threaded section of the screws acting as plug with
is falling between 0 and 4 Nm (0 - 0.4 kgm). IVECO sealant 1905683 and tighten to the specified torque.

526210 DIFFERENTIAL REPAIR OPER-

Figure 31 ATIONS
526260 Differential locking
Figure 33
62904
Position brake calliper (1) including the brake lining on the 62906
supporting flange (2).
Tighten the fastening screws to the specified torque. Remove the 4 screws (1) including washers and disconnect the
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differential locking device (2).
When refitting, replace the gasket located between differential
locking device and rear axle casing.
NOTE The brake lining with the wear sensor shall be fitted
Tighten screws (1) to the specified torque.
on brake calliper piston side.
Comply with BRAKE section requirements to move
back the brake calliper piston.
Figure 34
Figure 32
62907
DIFFERENTIAL LOCKING DEVICE SECTION
62880 Differential locking device engagement/disengagement lever

stroke shall be equal to 5 mm.
Remove the rear axle assembly from the overhaul stand. Refit
brake fluid pipes (2 and 3) to rear axle casing and brake
callipers (1).
Fill rear axle casing with oil in the specified amount and quality.

Differential unit removal Gearing case removal
NOTE Before performing differential repair, drain oil and Figure 38

remove axle shafts as described previously.
Figure 35
33081
Remove gearing case supporting bearings (1 and 2) using

puller 99348001 (3) and counter block 99345056 (4).
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Figure 39
33077
Remove gearing (1) inspection cover including the gasket.
Figure 36
33082
Clamp the gearing case (2) in a vice and remove the ring bevel
gear (1) from the gearing case (2).
33078
Remove caps (1) after marking them. Figure 40
Figure 37
33079
33083
Remove the spacer (1) and remove the gearing case (3) in- Mark gearing half-boxes (1 and 2), loosen the fastening
cluding the crown wheel (4) and the outer rings (2) for sup- screws, position the gearing case on a bench and remove the
porting bearings. Remove the other spacer and the adjust- two half-boxes.
ment rings. Do not reverse the outer races of the gearing case
supporting bearings.

Figure 41 Figure 44
33088
33084
Use a bronze beater in arrow direction to remove the bevel
Remove sun gears (5) and planetary gears (2) including the spi- pinion (1) including the rear bearing, the fixed spacer and the
der (6) from the gearing half-box (4). Recover the shoulder adjustment rings from the rear axle casing (2).
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washers (1 and 3).
Figure 42 Figure 45
33089
33086
Remove the sealing ring (1) and the front taper roller bearing
Remove bevel pinion retaining nut safety crimp and loosen from the rear axle casing (2). Use a bronze beater to remove
the nut using the counter lever 99370317 (1). the front taper roller bearing outer ring.
Figure 43 Figure 46
33090
33087
Use a bronze beater to remove the rear taper roller bearing
Remove transmission connection flange (1). outer ring (1) from the rear axle casing (2).

Gearing case refitting

Figure 47 Figure 48
33092
33091
Fit in place the sun gear (2) with the shoulder washer set
Use puller 99348001 (3) to remove the rear taper roller below in gearing half-box (1).
bearing (2) from the bevel pinion (1).
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Differential components check Figure 49
Carefully clean each differential component.

Lubricate the bearings and rotate the roller cage freely. The
rotation must be even and without sign of stiffness. Check the
ring bevel gear contact surfaces and the half-box striker plate
to ensure that the crown wheel adheres perfectly. Deforma-
tions on these surfaces cause the crown wheel fastening
screws to vibrate, thus jeopardizing the correct operation of
the unit.
NOTE Carefully clean all threads in order to obtain exact 33084

adjustments and accurate tightening torque. Fit in place the planetary gears (2) with shoulder washers (3),
the spider (6) and the sun gear (5) with shoulder washer (1)
in the gearing half-box (4).
Check that the splined section for flange-pinion connection is

not badly worn, otherwise replace the pinion.
Figure 50
NOTE When replacing the crown wheel or pinion it is

necessary to replace both parts since they are
supplied in pairs.
Check the planetary gears and the relevant shoulder

washers, the spider and the crown wheels with the relevant
shoulder washers.
Replace all sealing elements, the bevel pinion retaining nut
and gearing case bearing adjustment nut with new parts.
33094
Rear axle casing check
Fit between them the half-boxes (1 and 2) and tighten the
Check whether rear axle casing is not deformed. fastening screws to the specified torque.

Figure 51 Figure 54
33095 33098
Mount the outer ring of front taper roller bearing into rear axle
Heat in air-circulation furnace at 100ºC for approx. 15’ the box using beater 99374093 (1).
taper roller supporting bearing (1) on toothing side and fit it
down onto the gearing case (2) completely.
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Figure 52 Figure 55
33096
33099
Heat in air-circulation furnace at 100ºC for approx. 15’ the Use beater 99374093 (1) to fit in place rear taper roller
taper roller supporting bearing (1) on toothing opposite side bearing outer ring on rear axle casing (2) without adjustment
and fit it down onto the gearing case (2) completely. ring.
Figure 53 Figure 56
33097
33100
Pour few drops of LOCTITE 270 into crown wheel (1) holes, On surface plate (2), set to zero dial gauge 99395728 (1) on
fit the crown wheel (1) on the gearing case (2) and tighten the support (3) and slightly preload it.
fastening screws to the specified torque.

Figure 57 Figure 59
33101
33103
Fit the rear bearing (2) on the false pinion 99370296 (1). Set dial gauge 99395728 (1) including support (3) on false
pinion 99370296 (2).
Direct suitably the dial gauge previously set to zero (see
Figure 56) to position the rod to the bottom of the gearing
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case supporting bearing housing.
Figure 58 Repeat this operation for the other bearing and take note of
both found values.
Pinion adjustment ring thickness is obtained through the
following formula:
A1 + A2
S= -(±B)
2
”S” = thickness of the adjustment rings to be positioned

between bevel pinion rear bearing outer ring and rear axle
casing.
”A1” = value found on right housing
”A2” = value found on left housing
33102
”B” = reference value marked on bevel pinion (see Figure 60)
Example:
3,90 + 4,10
Position the false pinion 99370296 (1) including the rear bear- S= - ( ± 0,05)
ing (2) into its seat on rear axle casing (3). 2
Fit the front bearing, the transmission connecting flange and
the bevel pinion retaining nut and tighten so as to remove end 8,00
S= - 0,05
play and to enable false pinion rotation. 2
S = 4,00 - 0,05
S = 3,95
Adjustment ring thickness shall therefore be: 3.95 mm.

Figure 60 Figure 62
33104
32481
Heat the rear bearing (1) to 100°C for approx. 15’ into an
NOTE If the value marked on the pinion is preceded by air-circulation furnace and then fit it down onto the bevel
positive sign (+), it shall be subtracted from the pinion (2).
value obtained by the sum divided by two of the
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housings, whereas it shall be added if preceded by
negative sign (-).
Figure 63
32482
Figure 61
Position the fixed spacer (2) and the adjustment ring (3),
previously used to obtain the specified rolling torque, on the
bevel pinion (1).
Figure 64
33099
Choose an adjustment ring having the same thickness ob-

tained by using the formula shown in SENZA CODICE and
fit it into the rear axle casing after removing rear taper roller
bearing outer ring previously mounted.
Use beater 99374093 (1) to fit definitely the rear taper roller 33111
bearing outer ring into rear axle casing (2).
Position the complete bevel pinion into the rear axle casing.
Heat the front bearing (1) to 100°C for approx. 15’ into an
air-circulation furnace and then fit it down onto the bevel
pinion (2).

Figure 65 Figure 68
32480
Using the torque wrench 99389819 (1), measure the rolling

74730
torque of the bevel pinion.
Fit the seal ring (2) in the axle casing with tool 99374201 (1).
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Figure 66
If the value is incorrect disassemble the pinion (2, Figure 64),

and replace the adjuster ring (3, Figure 63) with a suitable ring.
33113
Fit the transmission connecting flange (1) and the bevel pinion
retaining nut (2).
Differential unit refitting
Figure 67 Figure 69
33116
74731
Assemble the flange (3) and prevent rotation with tool Fit gearing case supporting bearing outer rings (2) and then
99370317 (1). position the gearing case (1), previously fitted, in the rear axle
Using the torque wrench (2), tighten the bevel pinion flange casing.
(3) retaining nut to the correct torque value.

Figure 70 Figure 72
33107
Use dynamometric wrench 99389819 (1) to check total

33117
rolling torque:
Cd
Insert the spacer (2), adjuster ring (1), adjuster ring (4) and Ct = Cp + ( x 0.99)
then spacer (3). R
Ct = total rolling torque
Cp = bevel pinion bearing rolling torque
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Figure 71 Cd = 2 ÷ 2.8 Nm (0.2 ÷ 0.29 kgm)
R = Rear axle reduction ratio
Example:
2,8
Ct = 2.5 + ( x 0.99)
3,91
Ct = 2.5 + 0.71
Ct = 3.21 Nm (0.33 kgm)
If the value is incorrect, replace the adjuster rings (1 and 4,
Figure 70) with rings of the correct thickness.
Figure 73
33119
Refit caps (1) taking into account the marks made at removal.
Use dynamometric wrench 99389827 (2) to tighten the
fastening screws to the specified torque.
Set gearing case supporting bearings and check total rolling
torque.

33121
Position magnetic dial gauge 99395684 (1) and check the

clearance between the pinion and crown on four equidistant
teeth on the crown. The average of the measurements must
equal the required value. If a different clearance is found, remove
the caps (3) again and swap over the assembly position of the
adjustment rings (1 and 4, Figure 70).
If this is not sufficient, replace the adjustment rings with ones
of a different thickness, but the total thickness must still be the
same as that of the adjustment rings removed.
This is so as not to change the total rolling torque.
Apply a thin layer of Prussian blue on ring gear teeth by brush.
Turn the pinion and measure the impression of the contact of
the pinion toothing on the crown wheel toothing.
Here we illustrate the possible contacts with the corrections
to obtain precise coupling of the crown wheel and pinion.

Figure 74 Figure 77
44603
Excessive contact on heel
E = Greater base of tooth.
A = Coupling depth Move the ring bevel gear to-
F = Heel
B = Crest wards the pinion and then
G = Top land
C = Side move the pinion away from
H = Contact surface
D = Play the ring bevel gear to adjust
I = Lateral surface
44606
clearance.
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Figure 75 Figure 78
Excessive contact in the

upper part or crest of the
tooth.
Correct contact. Move the pinion towards
the ring bevel gear and then
move the ring bevel gear
44604
away from the pinion to ad-
44607
just clearance.
Figure 76 Figure 79
Excessive contact on side Excessive contact on the

of tooth. top land of the tooth.
Move the pinion away from Move the ring bevel gear
the ring bevel gear and then away from the pinion them
move the ring bevel gear to- move the pinion towards
wards the pinion to adjust the ring bevel gear to adjust
clearance. 44605 clearance. 44608

Figure 80 Figure 82
33122 33123
Fit a new sealing gasket on gearing inspection cover connec-

tion surface. Apply Loctite 270 on the thread of the holes for Fit oil drain plug (2). Pour 3 litres of W140/M-DA oil through
screws to secure cover (1). Fit cover (1) and use dynamomet- the proper hole and fit inspection and filling plug (1).
ric wrench to tighten the fastening screws to the specified
torque.
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NOTE Do not tighten screws at higher torque value since
this shall jeopardize the effect of the sealing gasket
located between the connection surface and the
gearing inspection cover.
Figure 81
* NUT ROTATION
DIRECTION
51853
Crimp nut (1) collar on bevel pinion (2) milling as shown in the
figure.

6 - Rear Axles

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6 - Rear Axles

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DAILY EURO 4 REAR AXLES 1

REAR AXLE NDA RS . . . . . . . . . . . . . . . . . . . . . 5

REAR AXLES NDA RG . . . . . . . . . . . . . . . . . . . . 35

REAR AXLE 450511 . . . . . . . . . . . . . . . . . . . . . . 53

REAR AXLE 450517/2 . . . . . . . . . . . . . . . . . . . . 83

Print 603.93.651 Base - March 2006

Base - March 2006 Print 603.93.651

1. - Wheel hubs noise;

1 WHEEL HUBS NOISE

Wheel hub bearings out of adjustment. Adjust bearings.

2 REAR AXLES NOISE

Wheel hub bearings inefficient. Adjust the bearings clearance.

Print 603.93.651 Base - March 2006

4 NOISE DURING ACCELERATION

Gear housing bearings badly set or deteriorated. Overhaul the unit.

Base - March 2006 Print 603.93.651

Rear axle NDA RS

SPECIFICATIONS AND DATA . . . . . . . . . . . . . 8

REAR AXLE NDA - RS REMOVAL - REFITTING 17

- Air breather disassembly - assembly . . . . . . . . 19

- Wheel hub overhaul . . . . . . . . . . . . . . . . . . . . 19

REPAIRING THE DIFFERENTIAL . . . . . . . . . . . . 22

- Disassembling the differential unit . . . . . . . . . . 22

- Gear housing removal . . . . . . . . . . . . . . . . . . . 23

- Dismounting bevel pinion . . . . . . . . . . . . . . . . 24

- Checking the parts comprising the differential 25

- Assembly of gear housing . . . . . . . . . . . . . . . . 26

- Assembling the bevel pinion assembly . . . . . . 27

- Assembly of differential unit . . . . . . . . . . . . . . 30

Print 603.93.651 Base - March 2006

Base - March 2006 Print 603.93.651

DESCRIPTION The adjustment of bearing rolling torque is through adjusting

Print 603.93.651 Base - March 2006

SPECIFICATIONS AND DATA

Type of rear axle:

1/3,154 (13/41) - 1/3,416 (12/41) - 1/3,727 (11/41) - 1/3,916

Bevel pinion bearings 2 with taper rollers

Bevel pinion bearings rolling torque

Position of bevel pinion with

Thickness of adjustment rings 3.585 ÷ 4.235 mm

Bearings for gear housing 2 with taper rollers

Differential casing bearings rolling

Adjustment of differential casing

Thickness of adjustment rings of 1 ÷ 1,95 mm

Base - March 2006 Print 603.93.651

Type of rear axle:

Adjustment of clearance between

Clearance between planetary and

Wheel hub bearings end play -

Wheel hub bearings rolling torque

Adjustment of wheel hub bearings Not adjustable

Rear axle oil TUTELA W90/M-DA (SAE 80 W 90)

Print 603.93.651 Base - March 2006

NDA RS REAR AXLE DIFFERENTIAL SECTION

Base - March 2006 Print 603.93.651

NDA RS REAR AXLE DIFFERENTIAL SECTION

Print 603.93.651 Base - March 2006

NDA RS REAR AXLE WHEEL HUB SECTION

Base - March 2006 Print 603.93.651

TOOL NO. DESCRIPTION