Dongfeng DFA1101GZ5AD6J-907. Manual - part 47

 

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Dongfeng DFA1101GZ5AD6J-907. Manual - part 47

 

 

Rear Axle

RA-4

Assembly and Adjustment

Disassemble and asseble of the assembly

Rear wheel hub brake drum assembly

1.Fixed the rear axle and remove the half axle bolt by a spanner;

2.Pull out the half axle gently and when the spline passing the oil seal, turn the half axle slowly to avoid damage

the half axle oil seal;

3.Take down three screws of the stop spacer by a screwdriver, then remove the stop spacer and dismantle the

adjusting nut by a spanner;

4.Turn the wheel hub brake drum a little and pull it, gently knock at the brake drum at the same time to loose the

inner ring of the outer bearing, then take down the wheel hub brake drum, but you need to pay attention that the
assembly is so heavy that may be fallen down or hurt someone, and the inner ring of the outer bearing need to
care at the same time, don't fall it.

The assembling sequence of the rear wheel hub brake drum assembly is opposite to the above sequence, and

you must to pay attention to the tightening torque of the thread connecting parts and the adjustment of the bearing
pretightening force.

Assembly of the main reductor assembly

1) Assembly of the drive gear

1.Press the outer ring of the front inner and outer bearing into the bearing seat;

2.Press the oil seal on the oil seal seat;

3.Press the inner ring of the front inner bearing onto the drive gear, and install the spacer sleeve, adjusting spacer,

bearing seat assembly and front outer bearing inner ring in sequence at the spline end of the gear;

4.Measure the pretightening load of the drive gear bearing: install the oil seal assembly, thrust washer, flange fork

and washer, then tighten the castle nut with a torque 350~500N.m and measure the pretightening force at this
time, the starting force of pulling the flange hole of the bearing seat should be 12~30N;

5.If the pretightening force is disqualified, you need to replace the adjusting spacer, reassemble to qualified;

6.Make use of a cotter pin to lock the castle nut.

2) Assembly of the differential

1.Install the bearing to the left and right differential housing;

2.Install planet gear, half axle gear, cross shaft, planet gear supporting washer, and half axle gear supporting

washer;

3.Measure the tooth space of the planet gear of the differential, check the clearance between half axle gear sup-

porting end face and the supporting washer with a clearance gauge, it should be ≤ 0.8 mm;

4.Align the marks of left and right differential housing and then assemble.

      Tightening torque: 140~160N.m

3) Assembly of the main reductor assembly

1.After assembled the bearing outer ring of the differential, install it onto the main reductor housing;

2.Install the adjusting nut and the bearing cover, then fasten with bolts;

3.Equably tighten the adjusting nut to pretighten the load until the pretightening load is between 16.4~24.3N;

4.Install the adjusting spacer of main cone to the bearing seat and assemble the drive conical gear assembly;

5.Adjust the gear tooth space to  0.20~0.40mm:

     The change value of the tooth space ≤ 0.15 mm

Rear Axle

RA-5

6.Paint two or three engaged teeth of driven gear red to chaeck the contact zone, if the contact area is improper,

increase or reduce the thickness of the adjusting spacer until it is proper;

Sketch map of the contact zone is as follows:

7.Tighten the bearing cover fixed bolt, reassemble the stop spacer.

Adjustment of the axle

Adjustment of the brake clearance

No matter if the brake clearance is too big or too small, it will effect the brake efficiency of the vehicle.

Please adjust the worm shaft hex-head of the adjusting arm by a spanner. Firstly, turn it with the clockwise until
you can't turn to make the clearance become zero, then turn with the counter clockwise until you hear two sounds
of steel ball, and the middle part clearance of the brake friction plate is 0.4~0.7mm.

Gear contact zone

Adjusting method

1

Proper contact zone

No need to adjust

2

The drive gear & the 
driven gear is too far

The drive gear and the driven 
gear is too far (reduce the 
thickness of the spacer)

3

The drive gear & the 
driven gear is too near

The drive gear and the driven 
gear is too near (increase the 
thickness of the spacer)

4

The contacting area of the 
driven taped gear is too 
low

The drive gear and the driven 
gear is too near (increase the 
thickness of the spacer)

5

The contacting area of the 
driven tapered gear is too 
high

The drive gear and the driven 
gear is too far (reduce the 
thickness of the spacer)

Rear Axle

RA-6

Adjustment of the rear wheel bearing pretightening force

1.Remove the stop spacer first;

2.Tighten the adjusting nut by a special spanner with a torque of 150~180N.m;

3.Turn the wheel hub 2~3 circles, and make the bearing aligned correctly;

4.Fasten the adjusting nut with a tightening torque of 150~180N.m;

5.Reverse the adjusting nut for 1/8~1/6circle;

6.Make sure if the pretightening force is correct. First, turn the wheel hub for 2~3 circles, then confirm the tangen-

tial force of the wheel hub bolt;

The tangential force of the wheel hub bolt is 30~ 60 N.

Trouble Analysis

Trouble

Cause

Method

Wheel hub bearing is 
stugnant

Big pretightening force of the wheel hub 
bearing

Adjust pretightening force

Bearing lack of lubricating or improper 
grease

Add or replace the grease

Dust on the bearing

Clean and add some grease

Insufficient brake force

Cam shaft turns inflexibly

Check the cam for its working condition

Improper adjustment of the brake air 
chamber push rod travel

Adjust travel

Friction plate overheated or deterioration

Replace friction plate

Improper connceting condition of the 
friction plate

Correct the joint position of friction plate

Water enterred the brake drum

Press down the brake pedal during 
running to exhaust the water

Grease on the connecting face of the 
friction plate or the brake drum

Cleanup the grease or replace friction 
plate

Abnormal noise while 
braking

Friction plate worn and rivet appeared

Replace friction plate

Friction plate surface hardening or deteri-
oration

Replace friction plate

Brake drum uneven worn or loose 
installed

Correct brake drum or tighten the bolt

Brake shoe and friction plate connected 
loosely

Replace rivet

Brake shoe fixed pin loosed

Tighten fixed pin locking screw

Wheel hub bearing worn

Replace wheel hub bearing

Brake drum distortion

Replace brake drum

Wheel unsmooth

Cam shaft lack of lubricating or adjusting 
arm doesn't return

Add grease or correct troubled parts

Return spring of the brake shoe or air 
chamber broken or fatigue 

Replace troubled parts

Rear Axle

RA-7

Lubricating Parts and Lubricant

Lubricating parts

Lubricant

Abnormal noise while 
driving

Improper gear space of the differential

Replace spacer or gear

Too big clearance between drive gear and 
driven gear 

Replace spacer or gear

Drive gear bearing pretightening force too 
small

Adjust pretightening force

Half axle gear, planet gear, and cross shaft 
worn or damaged

Correct or replace troubled parts

Oil level too low

Add enough lubricant

Lubricant leaks

Oil seal worn, loosed or damaged

Replace oil seal

Fasten bolt loosed or sealant failed

Tighten bolt or smear the sealant again

Bearing seat fasten bolt loosed

Tighten bolt by the required torque

Oil drain screw plug loosed or the gasket 
is damaged

Tighten screw plug or replace gasket

Axle housing distorted because of over-
load

Correct or replace axle housing

Vent is blocked or damaged

Clean or replace vent plug

Brake unstably 

Improper installation of the brake shoe or 
return spring is broken

Tighten fixed pin lock screw or replace 
return spring

Oil on brake friction plate or deterioration Clean or replace friction plate
Brake bottom damaged

Replace brake bottom plate

Item

Maintenance Interval Mileage ( × 1000km)

First maintain

4

8

12 16 20 24 28 32 36 40 44 48

Reductor assy

Wheel hub bearing

Adjusting arm

Cam bracket

Part

Lubricant

Type

Reductor assy

gear oil

GL-5 double curve gear oil

Wheel hub bearing

lithium grease

2# 

Adjusting arm

lithium grease

2# 

Cam bracket

lithium grease

2# 

 

 

 

 

 

 

 

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