6WG310 Typ-LK

Part No.
: 5871 177 102
ZF – DIFFERENTIAL CARRIER
TYPE: LK – TRANSMISSION MOUNTING
Supplement to Repair Manuals 6 WG-260 RPC / 6 WG-310 RPC
ZF Passau GmbH
Donaustr. 25 - 71
D- 94034 Passau
REPAIR INSTRUCTIONS
ZF – DIFFERENTIAL CARRIER
TYPE: LK – Transmission Mounting
Supplement to Repair Manuals 6 WG-260 RPC / 6 WG-310 RPC
Version: With Limited-Slip Differential DL-2400 (45% Locking Effect)
Note:
The great variety of ZF units compels a restriction of the Disassembly and Assembly Manuals to a
current ZF production unit. Technical development of the ZF units as well as extensions concerning
the design possibilities may require differing steps, which can be carried out by qualified Specialists
without greater difficulties with the help of the Perspective Illustrations in the corresponding Spare
Parts Lists.
The described Disassembly and Assembly Manual is based on the design level of a ZF production unit
at the time of preparation of the Repair Manual.
The ZF Passau GmbH reserve the right to replace the present Disassembly and Assembly Manual by
a successional edition without advance notice. Upon request, the ZF Passau GmbH will advise what
edition is the latest one.
ZF Passau GmbH
Donaustr. 25 - 71
D - 94034 Passau
Section : ASDM
Copyright ZF Passau GmbH!
With the reserve of technical mo difications!
Design level 2003/10
2. Edition 2004/11
Off-Road Transmissions
Repair Manual and Axle Systems
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PREFACE
This documentation has been developed for the skilled Serviceman, trained by the ZF Passau for the Repair
and Maintenance operations on ZF-Units.
Treated is a ZF -Serial product according to the design stage of the date of edition.
However, due to further technical developments of the product, the repair of the unit at your disposal could
require different steps as well as other adjustment and testing specifications.
Therefore, we recommend to commit your ZF-Product to Masters and to Servicemen, whose practical and
theoretical training is constantly completed to the actual situation in our Training School.
The Service Statio ns, established by the ZF Friedrichshafen all over the world, offer you:
1. Constantly trained personnel
2. Prescribed installations, e.g. Special Tools
3. Genuine ZF-Spare Parts according to the latest phase of development
Here, all operations are carried out for you with utmost care and reliability.
Repair operations carried out by ZF-Service Stations, are covered additionally within the terms of the actual
contractual conditions, by the ZF-Warranty.
Damages caused by inappropriate or inexpert work, carried out by personnel foreign to ZF, and after-
expenditures eventually arising from it, are excluded from this contractual responsibility.
This applies also in case of a renouncement of Genuine ZF-Spare Parts.
ZF Passau GmbH
Service Department
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GENERAL
The Service Manual covers all work required for dismantling and the pertaining installation.
When repairing the axle, ensure utmost cleanliness and that the work is carried out in an expert-like manner.
The axle should only be disassembled for renewing damaged parts. Covers and housing parts installed with
seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed. For
removing parts being in tight contact with the shaft such as antifriction bearings, bearing races, and similar,
use suitable pulling devices.
Dismantling and mounting work must be carried out at a clean working place. Use the special tools
developed for this purpose. Prior to the re- installation of the parts, clean the contact surfaces of housings
and covers from the residues of old seals. Remove burrs, if any, or similar irregularities with an oil stone.
Clean housings and locking covers with a suitable detergent, in particular corners and angles. Damaged
parts or parts heavily worn down must be renewed. Here, the expert must assess, whether parts such as
antifriction bearings, thrust washers etc. subjected to normal wear during operation, can be installed again.
Parts such as sealing rings, lock plates, split pins etc. must generally be renewed. Radial sealing rings with
worn down or torn sealing lip must also be renewed. Particularly ensure that no chips or other foreign
bodies remain in the housing. Lube oil bores and grooves must be checked for unhindered passage.
All bearings must be treated with operating oil prior to installing them:
REFE- For heating up parts such as bearings, housings etc., only a heating furnace or an electric
RENCE: drier is permitted to be used!
Parts fitted in heated state have to be installed subsequently after cooling down to ensure a
perfect contact!
CAUTION
When assembling the axle, absolutely observe the indicated torque limits and adjustment data. Screws and
nuts must be tightened according to the enclosed standard table, unless otherwise specified.
When installing snap rings and retaining rings pay attention to an exact contact in the grooves!
Lined plates with organic friction linings (e.g. paper linings) must not be washed
(negative effect on lining adhesion).
They are only allowed to be dry-cleaned (leather cloth).
DANGER
When using detergents, observe the instructions given by the manufacturer regarding
handling of the respective detergent.
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Structure of the Repair Manual
The structure of this Repair Manual reflects the sequence of the working steps for completely disassembling
of the dismantled unit.
Special tools required for performing the respective repair work are listed in the text as well as in the
Chapters “W” (List of Special Tools) and “WB” (Illustrated Tables).
Important information on industrial safety
Generally, the persons repairing ZF-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre -condition for avoiding
damage to persons and to the product during maintenance and repair work.
Persons performing repair work must familiarize themselves with these regulations.
The proper repair of these ZF-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
This symbol is indicated in this repair manual as reference to

F CAUTION special working procedures, methods, information, the use of
auxiliaries etc.
This symbol refers to situations, if lacking care can lead to

DANGER personal injury, danger to life and damages on the product.
____________________________________________
REFE- Prior to starting the checks and repair work, thoroughly study the present instructions.
RENCE
REFE- Illustrations, drawings and parts do not always represent the original; the working procedure
RENCE is shown.
The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The work must be performed according to the description.
REFE- After the repair work and the checks, the expert staff must convince itself that the product is
RENCE: properly functioning again.
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TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE

GLEASON GEAR-TOOTH SYSTEM
EXEMPLES POUR LA DENTURE GLEASON
Ideales Tragbild d.h. die Ritzeldistanz stimmt
Ideal tooth-contact pattern i.e. pinion distance is correct
L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte
Bild / Figure 1/3/5 Bild / Figure 1
Schubflanke (Konkav)
Coast side (concave)
Côté poussé (concave)
Bild / Figure 2/4/6 Bild / Figure 2
Zugflanke (Konvex)
Drive side (convex)
Côté entraîné (convexe)
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Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden
Pinion distance must be increased Pinion distance must be decreased
La distance du pigno n doit être augmentée La distance du pignon doit être diminuée
(+) (-)
Bild / Figure 3 Bild / Figure 5
Bild / Figure 4 Bild / Figure 6
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VERGLEICHSTABELLE FÜR MASSEINHEITEN

CONVERSION TABLE
TABLEAU DE CONVERSION
25,40 mm = 1 in ( inch)
1 kg ( Kilogramm ) = 2.205 lb ( pounds )
9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)
1.356 Nm ( 0.138 kpm ) = 1 lbf x ft ( pound force foot )
1 kg / cm = 5.560 lb / in ( pound per inch )
1 bar ( 1.02 kp/cm2 ) = 14.233 psi (pound force per square inch lbf/in2 )
=
0.070 bar ( 0.071 kp/cm2 ) 1 psi ( lbf/in2 )
=
1 Liter 0.264 Gallon ( Imp. )
=
4.456 Liter 1 Gallon ( Imp. )
=
1 Liter 0.220 Gallon ( US )
=
3.785 Liter 1 Gallon ( US )
=
1609.344 m 1 Mile ( Landmeile )
=
0° C ( Celsius ) + 32° F ( Fahrenheit )
=
0 ° C ( Celsius ) 273.15 Kelvin
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BEZEICHNUNG DER GESETZLICHEN EINHEITEN

DENOMINATION OF STANDARD DIMENSIONS
DENOMINATION DES DIMENSIONS STANDARDISEES
Hinweis : längenbezogene Maße in kg/m; flächenbezogene maße in t/m2
Note : linear density in kg/m; areal density in t/m2
Nota : Densité linéaire en kg/m; Densité superficielle en t/m2
Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

Unit Formula Sign New Old Conversion Note
Unité Symbole Nouveau Vieux Conversion Nota
Masse m kg (Kilogramm) kg
Mass
Mass
Kraft F N (Newton) kp 1 kp = 9.81 N
Force
Force
Arbeit A J (Joule) kpm 0.102kpm = 1J = 1Nm
Work
Travail
Leistung P KW (Kilowatt) PS (DIN) 1 PS = 0.7355 KW
Power 1 KW = 1.36 PS
Puissance
Drehmoment T Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm T (Nm) =
Torque F (N) . r (m)
Couple
Kraftmoment M Nm (Newtonmeter) kpm 1 kpm = 9.81 Nm M (Nm) =
Moment (Force) F (N) . r (m)
Moment (Force)
Druck (Über-) pü bar atü 1.02 atü = 1.02 kp/cm2
Pressure (Overpress) = 1 bar = 750 torr
Pression (Sur-)
Drehzahl n min -1
Speed
Nombre de Tours
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TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARD 148

Friction value: µ tot.= 0.12 for screws and nuts without after-treatment, as well as phosphatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following list:
Metric ISO-Standard thread DIN 13, Page 13

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100
Metric ISO-Fine thread DIN 13, Page 13
Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300
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1. DISASSEMBLY
Fasten the transmission to the assembly truck.
(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 071
Figure 1
1.1 Differential Carrier
Loosen the screw plug (arrow) and drain off the oil.
Figure 2
Remove the oil line.
Figure 3
Loosen the bolt connection (transmission/LK-drive).
Figure 4
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Rotate the transmission by 90°.
With the lifting tackle separate the differential carrier from the
transmission housing.
(S) Lifting chain 3-strand 5870 281 047
Figure 5
Remove the shim.
Figure 6
Fasten the differential carrier to the assembly truck.
Loosen the hexagon screws and by means of the forcing screws

separate the cover from the housing.
(S) Bracket 5870 350 089

(S) Forcing screws 5870 204 012
Figure 7
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Mark the radial installation position of the sealing holder

as well as of the bearing cover to the axle drive housing.
F Left or right sealing holder as well as bearing cover are

different; provide the single components with one or two
punch marks!
Then loosen the hexagon screws.
Figure 8
Fasten the differential by means of lifting tackle and separate the

flange shaft together with the bearing cover from the housing.
Remove the opposite flange shaft analogously.
Observe the instructions in Fig. 557!
(S) Lifting tackle 5870 281 013
Figure 9
Lift the differential by means of the lifting tackle out of the

housing.
Figure 10
Separate the bearing outer ring and the shim from the bearing
cover.
Figure 11
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Separate the flange shaft and sealing holder from the bearing
cover.
(S) Plastic hammer 5870 280 004
Figure 12
Unsnap the retaining ring and remove the shim.
(S) Set of external pliers 5870 900 015
Figure 13
Press the flange shaft out of the ball bearing.
Figure 14
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Pull the bearing inner ring from the differential housing.
Remove the opposite bearing inner ring analogously.
(S) Two -armed puller 5870 970 003
Figure 15
Loosen the locking screws.
Figure 16
Loosen both cap screws.
Figure 17
Separate the crown gear by means of the forcing screws from the
differential housing.
(S) Forcing screws 5870 204 008
Figure 18
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Take off the housing cover and remove the single components.
Figure 19
Heat the slotted nut (approx. 120° C).
F Slotted nut is locked with Loctite!
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 20
Loosen the slotted nut and remove the washer.
(S) Slotted nut wrench 5870 401 140

(S) Counter holder 5870 240 039
(S) Torque multiplier 5870 203 004
Figure 21
Pull the coupling sleeve from the input pinion.
Figure 22
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Press the input pinion out of the differential housing (Fig. 23)
and remove both bearing outer rings.
F Pay attention to released single components!
Figure 23
Press off the bearing inner ring from the input pinion.
(S) Gripping insert 5873 002 034
Figure 24
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1.2 Connection/Disconnection (Lock-Interaxle Differential)
Unsnap the retaining ring.
F To unsnap the retaining ring, lift the output shaft slightly!
Figure 25
Loosen the cap and hexagon screws.

Separate the selector housing by means of the pry bar set from
the transmission housing.
Figure 26
Remove the switch and the lock (arrow).
Figure 27
Preload the compression spring and remove the sliding sleeve.
Figure 28
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Remove the sealing cover and unsnap the retaining ring.
Figure 29
Drive out the bolt by means of striker from the bore and remove
the released single components.
(S) Striker 5870 650 001
Figure 30
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2. REASSEMBLY
2.1 Connection/Disconnection (Lock-Interaxle Differential)
Position the compression spring, piston and shift fork.
F Install the piston without stop screw and rectangular ring

first!
Figure 31
Insert the pin until contact and fasten it by means of the retaining
ring.
Then close the bore with the cover.
F Observe the installation position of the pin – thread for

extraction is showing outwards!
Wet contact face of the sealing cover with Loctite (Type
No. 262) !
Figure 32
Preload the compression spring and install the sliding blocks as

well as the sliding sleeve.
Figure 33
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Determine shifting position of sliding sleeve (Fig. 34 to 41):

X
To Figure 34:
1
2 1 = Selector housing
2 = Sliding sleeve
3 = Piston
4 = Shim
5 = Stop screw
6 = (S) Plug gauge 5870 200 130
Installation dim. X = 7.2 + 0.1 mm
Adjusting dim. Y = 34.5 +0.3 mm
F
6 With the plug gauge 5870 200 130 (Item 6) the installation
dim. X = 7.2 + 0.1 mm is fixed (Fig. 35 and 36) !
3
4
5
Figure 34
+ 0.1
Fix the installation dim. X = 7.2 mm by means of the plug
gauge (Fig. 35 and 36 ):
Introduce the plug gauge.
(S) Plug gauge 5870 200 130
Figure 35
Install the plug gauge by means of the two-armed puller until

contact and fix it.
Figure 36
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Fix the selector housing in the vice.
Figure 37
Insert the stop screw into the measuring fixture.
F Use assembly grease !
(S) Measuring fixture 5870 200 107
Figure 38
Insert the measuring fixture and locate it at the mounting face

until contact.
Figure 39
Determine Dim. Z, see figure on the left.
Dim. z e.g. .......................................... 33.00 mm
Figure 40
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Example:
Adjusting dim. Y (34.5 + 0.3 mm) e.g. ........ 34.60 mm

Dim. Z ...................................................... – 33.00 mm
Difference = Shim s = 1.60 mm
Remove the measuring fixture and the plug gauge again.
Insert shim e.g. s = 1.6 mm (arrow) and install the cap screw.
Use screw locking – Loctite 243 !
F Tightening torque (M10/8.8) .............. M A = 46 Nm
Figure 41
Insert the rectangular ring (arrow) into the annular groove of the
piston.
Figure 42
Provide the mounting face with sealing compound (Three Bond

Type 1215 / ZF Part No.: 0666 790 054.
Insert the axle disconnection cautiously and locate the cap and
hexagon screws until contact evenly.
Figure 43
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Insert both cyl. pins (arrow) until contact.

Then fasten the selector housing finally with the cap and
hexagon screws.
Tightening torque (M10/8.8) ....................... M A = 46 Nm
Figure 44
Introduce the retaining ring into the recess of the output shaft.
F Lift the output shaft slightly to have the retaining ring

snapped in.
Figure 45
Install the switch ( Fig. 46 ... 48):

To Fig. 46:
1 = Switch
2 = O-ring
3 = Lock
3 2 1
Figure 46
Insert the lock and install the switch (arrow).
Tightening torque ............................ M A = 50 Nm
Figure 47
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Check function of the switch by resistance measurement !
Actuating the dis-/connection by means of compressed air

results in a changed resistance at an intact switch !
(S) Measuring (Multimeter) 5870 221 196
Figure 48
To Fig. 49:
1 = Perforated sheet
2 = Filter insert
3 = Plug
1
2
3
Figure 49
Insert the perforated sheet (1) and filter insert (2) into the
housing bore (arrow).
Until installation of the pressure line, seal the bore by means of
the plug (3).
Figure 50
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2.2 Input Pinion
Note: If crown gear or input pinion are damaged, both parts (bevel gear set) have to be replaced together !
Pay attention to same pair number !
Contact pattern – Adjustment of bevel gear set ( Figure 51 ... 58)
Note: Carry out the following measuring procedures with utmost accuracy !
Inexact measurements result in an erroneous contact pattern !
To Fig. 51:
1 = Plug gauge ........................ (S) 5870 351 016

2 = Stop washer ...................... (S) 5870 351 019
3 = Adapter piece.................... (S) 5870 500 015
4 = Measuring shaft ............... (S) 5870 500 001
X=a+b+c
Figure 51
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Insert the stop washer (2) and plug gauge (1) into the bearing
bore (input pinion).
(S) Stop washer 5870 351 019

(S) Plug gauge 5870 351 016
Figure 52
Insert both adapter pieces (3) into the bearing bores (differential
bearing).
(S) Adapter pieces 5870 500 016
Figure 53
Insert the measuring shaft (4).
(S) Measuring shaft 5870 500 001
Figure 54
Measure Dim. b by means of feeler gauge.
Dim. b e.g. ......................................... 0.50 mm
EXAMPLE “ O1“ :
Dim. a (stop washer + plug gauge) 226.00 mm

Dim. b e.g. ........................................ + 0.50 mm
Dim. c (1/2 ∅ measuring shaft) ....... + 15.00 mm
results in Dim. X e.g. = 241.50 mm
Figure 55
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Read Dim. I (pinion dimension, see arrow).
Dim. I e.g. ......................................... 198.00 mm
Figure 56
Measure Dim. II (bearing height).
Dim. II e.g. ............................................... 42.30 mm
EXAMPLE: “O 2“ :
Dim. I e.g. ........................................ 198.00 mm
Dim. II e.g. ........................................ + 42.30 mm
results in Dim. Y = 240.30 mm
(S) Gauge blocks 5870 200 066

(S) Straightedge 5870 200 022
Figure 57 (S) Digital depth gauge 5870 200 072
EXAMPLE: “ O 3“:
Dim. X ............................................... 241.50 mm

Dim. Y ............................................... - 240.30 mm
Difference = Shim s = 1.20 mm
Place shim (e.g. s = 1.20 mm) and insert the bearing inner ring
until contact.
(S) Mounting tool 5870 050 009

(S) Handle 5870 260 004
Figure 58
Rotate the differential housing by 180°.
Insert the bearing outer ring until contact.

(S) Handle 5870 260 002
Figure 59
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Press the bearing inner ring over the input pinion until contact.
Figure 60
Adjust the rolling moment of the input pinion bearing

T = 3.5 ... 4.5 Nm (without shaft seal) (Fig. 61 ... 65):
Install the adjusting ring e.g. s = 8.15 mm.
F
As per experience the required rolling moment is
obtained by use of the adjusting ring (e.g. s = 8.15 mm)
available at disassembly!
However, a later checking of the rolling moment is
mandatory!
Figure 61
Position the input pinion and install the heated bearing inner ring
until contact.
Wear safety gloves!
Figure 62
Install the coupling sleeve.
Figure 63
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Mount the washer and tighten the slotted nut.
Tightening torque .............. M A = 1200 Nm
F When tightening rotate input pinion in both directions

several times!

(S) Torque mult iplier 5870 203 004
Figure 64
Check the rolling moment T = 3.5 ... 4.5 Nm!
F If the required rolling moment is not obtained, correct it with

an adequate adjusting ring (Figure 61)!
- Rolling moment too low – install a thinner ring!
- Rolling moment too high – install a thicker ring!
Upon adjustment of the rolling moment, loosen the slotted nut

again and remove the coupling sleeve.
(S) Torque wrench 5870 203 019

(S) Connecting piece 5870 656 073
Figure 65
Install both shaft seals.
F Observe the installation position, also see Fig. 67 !

The exact installation position is obtained by using the
specified installation position !
Wet the outer diameter of the shaft seals with sealing
compound (Loctite, Type No. 574)!
Wet the sealing lip!
Figure 66
Figure 67
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Mount the coupling sleeve.

Install the washer and tighten the slotted nut finally.
F Wet the thread of the slotted nut with Loctite (Type No. 262)!
When tightening rotate the pinion in both directions several
times!
Tightening torque ................... M A = 1200 Nm

(S) Torque multiplier 5870 203 004
Figure 68
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2.3 DIFFERENTIAL DL-2400, locking effect 45%
The following perspective illustration shows the single components of the differential and their installation
position.
1 = Cap screws (2x) 7 = Thrust ring

2 = Housing cover 8 = Axle bevel gear
3 = Thrust washer (steel) 9 = Differential bevel gear
4 = Thrust washer (brass) 10 = Differential axle
5 = Outer clutch disc (optional) 11 = Differential housing
6 = Inner clutch disc
Figure 69
Note:
To adjust the mounting clearance of the internal components ( Fig. 78 ... Example “ P “), outer clutch discs
of different thickness are available (s = 2.7 ... 3.3 mm)!
The outer clutch discs are to be selected in a way that the height of the disc sets A and B is identical on both
sides!
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For the following assembly sequence observe the installation

position of the single components, also see perspective
illustration/Page 1/22 ! Oil the single components to ZF List
of Lubricants TE-ML 05 !
Install both thrust washers.
Figure 70
Insert the disc set A alternately, starting with an outer clutch

disc.
Figure 71
Insert the thrust ring.
Figure 72
Introduce the axle bevel gear until both inner clutch discs are
located.
Figure 73
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Insert the complete differential spider.
Figure 74
Install the second axle bevel gear.
Figure 75
Insert the thrust ring.
Figure 76
Install disc set B alternately, beginning with one inner clutch

disc.
Figure 77
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Check mounting clearance of the internal components

= 0.2 ... 0.8 mm (Fig. 78 ... Example “ P “):
Determine Dim. I, from the mounting face to the outer clutch

disc.
Dim. I e.g. ........................................ 4.30 mm
(S) Digital depth gauge 5870 200 072

Figure 78
Measure Dim. II, from the contact face to the mounting face.
Dim. II e.g. ....................................... 3.95 mm

Figure 79
EXAMPLE “ P “:
Dim. I e.g. ........................................ 4.30 mm

Dim. II e.g. ....................................... - 3.95 mm
Difference ^ Mounting clearance = 0.35 mm
F For mounting of new discs it should be tried to achieve the

lower value!
Corrections are to be made with adequate outer clutch
discs!
Observe note, Page 1/22!
Fix both thrust washers with grease in the housing cover.
Figure 80
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Fasten the housing cover by means of two cap screws.
Tightening torque (M10/8.8) ................ M A = 46 Nm
Figure 81
Install the adjusting screws (3 pcs.) and press the differential into
the crown gear until contact.
(S) Adjusting screws 5870 204 040
Figure 82
Fix the differential by means of the press.
Bolt together the crown gear, differential housing and housing

cover.
Tightening torque (M16x1.5/12.9).................... M A = 385 Nm
F Only new locking screws are allowed to be used!
Figure 83
Press the crown gear-sided as well as the opposite bearing inner

ring until contact.
Figure 84
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Put the differential by means of the lifting tackle into the axle
drive housing.
(S) Gripping tongs 5870 281 013.
Figure 85 Adjust (Fig. 86 ... 97 ):

backlash – crown gear set = 0.20 ... 0.30 mm
and
bearing rolling moment – differential T = 3 ... 4 Nm:
Put shim e.g. s = 2.40 mm into the bearing cover I (crown gear-
side).
F Both bearing covers of the differential bearing are different!

Pay attention to markings made at disassembly !
By experience the required backlash is obtained by using the
shim (e.g. s =2.40 mm) from the disassembly! However, a
later checking of the backlash is mandatory!
Figure 86
Insert the bearing outer ring.
Figure 87
Install the O-Ring (arrow).
Figure 88
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Install two adjusting screws.
Insert bearing cover I and fasten it with four screws

preliminarily .
Tightening torque ................... M A = 79 Nm
Figure 89
Rotate the axle drive housing by 90°.
Put on the bearing outer ring, press it on evenly and determine

Dim. I, from the mounting face to the bearing outer ring.
Dim. I e.g. ........................................ 41.60 mm

Figure 90
Bearing cover II (opposed to crown gear side):
Measure Dim. II, from the mounting face to the contact face-
bearing outer ring.
Dim. II e.g. ........................................ 39.90 mm
Figure 91
EXAMPLE “ R “:
Dim. I e.g. ......................................... 41.60 mm

Dim. II e.g. ....................................... - 39.90 mm
Difference ........................................ = 1.70 mm
required bearing preload e.g. + 0.30 mm
results in shim s = 2.00 mm
F The bearing preload = 0.3 ... 0.4 mm corresponds with the

required bearing rolling moment T = 3 ... 4 Nm!
Install shim e.g. s = 2.00 mm and bearing outer ring.
Figure 92
5871 177 102 1/28

Division
Install the O-ring (arrow).
Figure 93
Install two adjusting screws.

Insert bearing cover II and by means of four screws locate it until
contact evenly.
Tightening torque ........................... M A = 79 Nm
F When tightening the screws, rotate the crown gear in both

directions several times!
Then relieve the differential bearing by blowing slightly onto
both bearing covers (use a plastic hammer)!

Figure 94
Rotate the axle drive housing by 90°.
Locate the dial indicator rectangularly at the outer ∅ of a tooth

flank and check the backlash.
(S) Magnetic stand 5870 200 055

(S) Dial indicator 5870 200 057
F If corrections of the backlash are required, pay attention to

the following instructions!
Figure 95 1. Backlash too low:

Install a thinner shim on the crown gear-sided bearing cover I
(Fig. 86).
Shim to determine the bearing preload (bearing cover II, Fig. 92)
has to be selected correspondingly thicker!
2. Backlash too high:

Install a thicker shim on the crown gear-sided bearing cover I
(Fig. 86).
Shim to determine the bearing preload (bearing cover II, Fig. 92)
has to be selected correspondingly thicker!
5871 177 102 1/29

Division
Check the contact pattern (Fig. 96 and 97):
Wet some coast and drive sides of the crown gear with marking
ink.
Figure 96
Roll the crown gear several times in both directions over the
input pinion.
Compare the resulting contact pattern with contact pattern

examples, Page 0/4 and 0/5.
F In case of a contact pattern deviation a measuring error was

made at determination of the shim (Figure 58) which is
necessary to be corrected!
Figure 97
5871 177 102 1/30

Division
2.4 Preassembly and Installation of the Flange Shaft
Put the sealing holder over the plane support.

Press in the shaft seal with the sealing lip showing to the oil
chamber.
F Wet the outer diameter with spirit!

Grease the sealing lip!
The exact mounting position is obtained by use of the
specified special tool (S)!

Figure 98
Insert the sealing holder and press the ball bearing over the shank
of the flange shaft until contact.
Figure 99
By means of the shim and the retaining ring adjust the ball
bearing backlash-free.
(S) Set of external pliers 5870 900 015
Figure 100
Install the O-ring (arrow).
Figure 101
5871 177 102 1/31

Division
Heat the bearing bore (approx. 90° C).
(S) Hot-air blower 230 V 5870 221 500

(S) Hot-air blower 115 V 5870 221 501
Figure 102 Insert the flange shaft and fasten it evenly by means of hexagon
screws.
Tightening torque (M12/8.8) .............. M A = 79 Nm
F Left and right sealing holder are different!

Observe the mounting position and the radial installation
position, see markings made at disassembly!
Then install the opposite flange shaft analogously (Fig. 98 ...

103).
F After mounting of both sealing holders, relieve the

differential bearing by means of slight blows (use a plastic
hammer)!
Figure 103 (S) Plastikhammer 5870 280 004
Wet the mounting face with sealing compound (Loctite, Type

No. 574).
Install two adjusting screws and locate the cover until contact.
Observe the radial installation position!
F (S) Adjusting screws 5870 204 021
Figure 104
Fasten the cover by means of hexagon screws (do not tighten it)
and flush-mount both slotted pins.
Then fasten the cover finally by means of hexagon screws.
Tightening torque (M12/10.9) .................. M A = 115 Nm
Figure 105
5871 177 102 1/32

Division
Install the mounting pipe and the breather, see arrow!
F Install new sealing ring (Cu)!
Figure 106 2.5 Mounting of Diff. Carrier to Transmission.

Adjust axial play-output shaft 0.3 + 0.2 mm (Fig. 107...111):
Figure 107
Measure Dim. I, from the end face – coupling sleeve to the

mounting face.
Dim. I e.g. ........................................ 291.90 mm

(S) Depth gauge 5870 200 086
Figure 108
5871 177 102 1/33

Division
Measure Dim. II, from the end face – coupling sleeve to the end
face – input pinion.
Dim. II e.g. ...................................... 49.00 mm
EXAMPLE “ S1 “
Dim. I e.g. ....................................... 291.90 mm

Dim. II e.g. .................................... - 49.00 mm
results in Dim. X e.g. 242.90 mm
Figure 109
Housing dimension:
Locate the output shaft until contact in direction of the arrow.
Determine Dim. Y, from the mounting face to the end face –

output shaft.
Dim. Y e.g. ....................................... 246.80 mm

(S) Depth gauge 5870 200 086
Figure 110
EXAMPLE “ S 2 “ :
Dim. Y e.g. .............................................. 246.80 mm

Dim. X e.g. .............................................. - 242.90 mm
Difference .................................................. = 3.90 mm
required axial play (0.3 + 0.2 ) e.g. ... - 0.40 mm
results in shim e.g. s = 3.50 mm
Fasten the shim (arrow 1) by means of assembly grease to the

end face of the input pinion.
Install and grease the O-ring (arrow 2 ).
2
1
Figure 111
5871 177 102 1/34

Division
Introduce the differential carrier by means of the lifting tackle

until contact.
(S) Lifting chain 5870 281 047
Figure 112
Rotate the transmission by 90°.
Fasten the differential carrier by means of cap screws to the

transmission housing.
Tightening torque (M30/10.9) .......... M A = 1900 Nm
Then install the oil line (arrow).
F Prior to commissioning of the unit fill up oil according to the

data in the operating instructions!
Figure 113
5871 177 102 1/35

6WG310 Typ-LK

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Part No.

: 5871 177 102

TYPE: LK – TRANSMISSION MOUNTING

Supplement to Repair Manuals 6 WG-260 RPC / 6 WG-310 RPC

Supplement to Repair Manuals 6 WG-260 RPC / 6 WG-310 RPC

Version: With Limited-Slip Differential DL-2400 (45% Locking Effect)

1. Constantly trained personnel

2. Prescribed installations, e.g. Special Tools

3. Genuine ZF-Spare Parts according to the latest phase of development

5871 177 102 0/1

5871 177 102 0/2

Structure of the Repair Manual

Important information on industrial safety

The repairer is obliged to perform the training.

This symbol is indicated in this repair manual as reference to

This symbol refers to situations, if lacking care can lead to

5871 177 102 0/3

TRAGBILDBEISPIELE ZUR GLEASONVERZAHNUNG

EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE

EXEMPLES POUR LA DENTURE GLEASON

Ideales Tragbild d.h. die Ritzeldistanz stimmt

Ideal tooth-contact pattern i.e. pinion distance is correct

L'engrènement idéal, c'est-à-dire, la distance du pignon est correcte

Bild / Figure 1/3/5 Bild / Figure 1

Coast side (concave)

Côté poussé (concave)

Bild / Figure 2/4/6 Bild / Figure 2

Drive side (convex)

Côté entraîné (convexe)

5871 177 102 0/4

Ritzeldistanz muß größer werden Ritzeldistanz muß kleiner werden

Pinion distance must be increased Pinion distance must be decreased

Bild / Figure 3 Bild / Figure 5

Bild / Figure 4 Bild / Figure 6

5871 177 102 0/5

VERGLEICHSTABELLE FÜR MASSEINHEITEN

1 kg ( Kilogramm ) = 2.205 lb ( pounds )

9.81 Nm ( 1 kpm ) = 7.233 lbf x ft ( pound force foot)

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

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

5871 177 102 0/6

BEZEICHNUNG DER GESETZLICHEN EINHEITEN

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

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

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

Begriff Formelzeichen Neu Alt Umrechnung Bemerkungen

5871 177 102 0/7

TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARD 148

Metric ISO-Standard thread DIN 13, Page 13

5871 177 102 0/8

Fasten the transmission to the assembly truck.

(S) Assembly truck 5870 350 000

1.1 Differential Carrier

Remove the oil line.

Loosen the bolt connection (transmission/LK-drive).

5871 177 102 1/1

Rotate the transmission by 90°.

(S) Lifting chain 3-strand 5870 281 047

Remove the shim.

Fasten the differential carrier to the assembly truck.