Central Gear R560/660/665: en-GB

08:05-03
Issue 2.4 en-GB
Central gear R560/660/665
Work description
©
1 712 916 Scania CV AB 2010, Sweden
Contents
Contents
General Cleanliness................................................................ 3
Safety........................................................................ 3
Exploded view drawing............................................ 4
Setting press force .................................................... 6
Oil ............................................................................. 7
Spot repairs Oil/air leak in differential lock actuating unit .......... 8

Renewing sealing ring on pinion............................ 10
Reconditioning Removing and fitting the central gear .................... 14

Reconditioning the differential and renewing
the crown wheel...................................................... 22
Reconditioning the pinion and pinion bearing
housing, and adjusting the pinion height................ 28
Removal and dismantling ....................................... 32
Assembly and adjustment....................................... 36
Adjusting pinion height .......................................... 42
Adjusting backlash and bearing preload................. 43
Checking mesh image............................................. 46
Fitting the differential lock actuating unit parts
and adjusting the clearance..................................... 51
Specifications General ................................................................... 53

Tightening torques.................................................. 54
Setting and check values ........................................ 55
2 ©
Scania CV AB 2010, Sweden 08:05-03
General
General
The difference between the R560, R660 and Safety

R665 is the diameter of the half shafts and the
inside diameter of the differential gear splines.
This work description applies to both trucks
and buses. ! WARNING!
Central gear for buses with ground gear set Never work under a vehicle with air
(crown wheel and pinion), has a different suspension, which is not fully secured
backlash, and a different mesh image. against falling, in case there is a
change of pressure in the air bellows.
For adjusting the backlash and bearing preload There is a risk of getting trapped and
and checking the mesh image for this type of injured.
central gear, see separate work description
below. Both the chassis and moving axle
suspension components must be
secured against falling with axle stands
to ensure absolute safety when
working under a vehicle.
Cleanliness
Cleanliness is extremely important when
working with central gears. Contamination
reduces their service life considerably. Always
clean the outside of the central gear housing
and rear axle housing before removing the
central gear. Before assembling the central
gear, all parts, old as well as new, must be
cleaned.
08:05-03 ©
Scania CV AB 2010, Sweden 3
General
Exploded view drawing
4 ©
General
1 Nut 41 Adjusting ring

2 End yoke 42 Lever
3 Dust cover 43 Bracket
4 Sealing ring 44 Shaft
5 Seal seat 45 Internal hexagon screw
6 Tapered roller bearing 46 Fork stud
7 Shim 47 Shim
8 Spacing ring 48 Cylinder
9 Bearing housing 49 Sealing ring
10 Screw 50 Pull rod
11 Cup spring 51 Piston
12 Plate 52 Flange nut
13 Tapered roller bearing 53 O-ring
14 Shim 54 Spring
15 Gear housing 55 Cover
16 Bearing cap 56 O-ring
17 Pinion 57 Washer
18 Crown wheel 58 Screw
19 Differential housing half 59 Switch
20 Screw 60 Screw
21 Nut 61 O-ring
22 Tapered roller bearing 62 Half shaft
23 Adjusting ring 63 Cover (alternative)
24 Roller bearing 64 Screw
25 Circlip
26 Screw
27 Steering
28 Set screw
29 Coupling half
30 Wear washer
31 Differential gear
32 Differential spider
33 Differential pinion
34 Wear washer
35 Differential gear
36 Wear washer
37 Differential housing half
38 Washer
39 Screw (new type: Torx screw, old type:
Internal hexagon screw)
40 Tapered roller bearing
08:05-03 ©
General
Setting press force

The press force obtained is directly dependent
on the hydraulic pressure from the pneumatic
pump 99 004. The pump’s hydraulic pressure is
dependent on the supplied air pressure, which is
regulated with a pressure regulator.
The air pressure can be changed with an
adjusting knob. Pull the red retaining ring
towards the adjusting knob and set the desired
pressure which can be read on the manometer.
A line chart on the pump housing specifies the
desired press force from the hydraulic cylinder
as a function of the air pressure input to the 1 Compressed air connection.
pump. The line chart is shown below. 2 Manometer.
3 Adjusting knob for air pressure.
4 Pump housing line chart.
Set the press force to 120 kN (12 tonnes) as

follows:
1 Follow the press force axis (the bottom axis)
to the right until you reach 120 kN.
2 Then follow the line straight up until it cuts
the bold diagonal line.
3 Draw a horizontal line to the left from this
intersection. This gives a value of 5.2 bars,
which is the pressure required for 120 kN
press force.
6 ©
General
Oil
For the correct oil grade, refer to Workshop
Manual Oils, fluids and lubricants in main
group 0.
! WARNING!
Use protective goggles when draining

oil from the central gear. Oil can spray
out at high pressure.
Help protect our environment. Dispose of excess

oil in accordance with workshop procedures and
local regulations.
08:05-03 ©
Spot repairs
Spot repairs
Oil/air leak in differential lock

actuating unit
Dismantling
1 Loosen the screws (2), but leave them threaded a
few turns.
! WARNING!
The cover is spring loaded and can fly off

when the sealant releases.
2 Remove the screws (3), tap the cover (4), so that

the sealant releases. Remove the cover and the
compression spring.
3 Heat the nut (6) which is secured with locking
compound. Loosen the nut, but leave it threaded
on a few turns.
4 Blow air through hole A into the cylinder so that
the piston is forced out. Remove the nut and
piston.
5 Screw the threaded part of tool 98 726 onto the
pull rod, to prevent the pull rod from falling into
the gear housing (the tool must be machined as
illustrated).
6 Remove the cylinder from the gear housing.
Keep the shim(s).
8 ©
Spot repairs
Numbers in brackets refer to the illustration for

dismantling.
Assembly
1 Clean the parts carefully.
2 Fit a new greased sealing ring (9) as
illustrated, the shim(s) (13), and a new
greased O-ring (12) and fit the cylinder.
3 Fit a new greased O-ring on the piston and
fit the piston.
4 Apply locking compound to the thread,
screw on the nut, and tighten to 20 Nm.
5 Fit a new O-ring (10) in the air duct, fit the
spring, apply sealant to the cover (be careful
around the screw holes) and screw on the
cover.
6 Check the function of the switch. The circuit
should be closed when the differential lock
is engaged.
08:05-03 ©
Spot repairs
Renewing sealing ring on

pinion
Tool
Number Denomination Picture Tool board

88 292 Pull rod 88 292 G2
00 1848
98 257 Support drift 98 257
G2, AM2
110 076
98 568 Support drift 98 568
R2
00_1618
98 765 Splined socket 98 765

00_1642
G2
99 001 Adapter H1
99 003 Hydraulic cylinder H1
99 004 Hydraulic pump H1
99 005-1 Pusher adapter 99 005−1

G1, H1
111 423
99 010 Plain bush H1
10 ©
Spot repairs

99 011 Threaded bush H1
99 012 Threaded spindle 99 012

H1
109 431
99 040 Pusher adapter 99 040
H1
110 995
99 124 Puller 99 124 G1, H1
110 253
99 129 Counterhold 99 129 G2
00_1616
99 377 Drift 99 377

R3
112 705
587 318 Puller XA3

114 693
587 319 Puller XA3
08:05-03 ©
Spot repairs
Dismantling
Figure 2:
• Remove the end yoke using the tools as
illustrated.
Figure 3:
• The seal can separate into two parts. One
part is mounted on the end yoke and the
other on the seal seat.
• Remove the part in the seal seat carefully.
Make sure the surface in the seal seat is not
damaged.
• Carefully remove the dust cover and the seal
part which is fitted on the end yoke. Use the
tools as illustrated. Make sure the surface of
the end yoke is not damaged.
12 ©
Spot repairs
Assembly
Figure 1:
• Renew the dust cover if it is damaged.
• Press on the new sealing ring.
Figure 2:
• Press on the end yoke with the tool as
shown in the picture. Complete with a press
force of 100 kN. Refer to Setting press
force.
IMPORTANT! Never strike the end yoke. Risk

of bearing damage.
Figures 3a and 3b:

• Fit a new nut and tighten it to 1,000 Nm
with a large torque wrench, or tighten the
nut to the same torque by first tightening it
to 300 Nm and then a further 26 mm.
Figure 4:
• Lock the nut by staking it into both recesses
in the end yoke.
08:05-03 ©
Reconditioning
Reconditioning
Removing and fitting the

central gear
Tool

98 401 V block 98 401 F2
00 1899
98 402 Holder for fixture shaft F1
98 403 Fixture shaft F1

00 1644
98 403
98 404 End yoke bracket 98 404 F1

114 965
98 405 Bracket and fixture beam F1
14 ©
Reconditioning

587 313 Jack A
102 902
08:05-03 ©
Reconditioning
Removing
! WARNING!
Never work under a vehicle with air

suspension, which is not fully secured
against falling, in case there is a change
of pressure in the air bellows. There is a
risk of getting trapped and injured.
Both the chassis and moving axle
suspension components must be
secured against falling with axle stands
to ensure absolute safety when working
under a raised vehicle.
• Take the load off the axle housing before

removing the central gear.
• Vehicles with leaf spring suspension must
be supported under the frame or springs as
illustrated.
! WARNING!
Use protective goggles when draining

oil. Oil can spray out at high pressure if
the rear axle housing ventilation is
blocked.
16 ©
Reconditioning
Vehicles with connecting member:

• Loosen the nuts for the spring bolts (3), but
leave them threaded a few turns.
• Tap in the spring bolts slightly.
• Remove the screws (2) and keep the
shims (4).
• Remove the connecting member (1).
1 Loosen the nuts for the half shaft flanges,

but leave them threaded a few turns. Clean
the puller threads with a pilot tap, and screw
in three screws so that the flange exerts
tension on the cones. Carefully tap on the
half shaft flange with a copper sledge
hammer until the cones come loose.
IMPORTANT! Do not tap in the area marked in

grey, since there is a high risk of damaging the
half shaft flange, resulting in leakage.
2 Remove the nuts, cones and half shaft

flanges, and pull out the half shafts approx.
20 cm.
3 Drain the oil from the axle housing (also
refer to the oil section).
4 Detach electric wiring and compressed air
lines for the differential lock.
5 Remove the propeller shafts as described in
the work description under main group 6.
6 Remove obstructing brake components as
described in work description under main
group 10.
08:05-03 ©
Reconditioning
7 Undo all nuts except two (one in each upper

corner) securing the central gear.
8 Attach the central gear to the jack using the
tool as illustrated.
9 Remove the two remaining nuts securing
the central gear and pull it out from the rear
axle housing.
! WARNING!
Be careful during this procedure. Do not

stand at the side of the gear. Risk of
crush injuries if it tips over.
18 ©
Reconditioning
Fitting
1 Clean the axle housing internally and
degrease the sealing surface to the axle gear.
Torque tighten the oil drain plug to 100 Nm.
2 Fit a new filter.
3 Make sure all the studs are secure in the rear
axle housing. Loose studs must be removed
and fitted with locking compound
(Part No. 561 029) on the threads. Torque
tighten the studs to 80 Nm.
4 Clean the central gear sealing surface.
IMPORTANT! Complete cleaning by grinding

both sealing surfaces with long, sweeping
movements using an emery cloth with a grain
size of 80-120 to improve gasket adhesion.
5 Fit the paper gasket on the axle housing by

hanging it on the studs and pressing the end
in towards the sealing surface.
6 Assemble the jack and the fixture parts as
illustrated. Align the central gear on the jack
fixture. Tighten the end yoke in the end
yoke bracket.
08:05-03 ©
Reconditioning
! WARNING!
Be careful during this procedure. Do not

stand at the side of the gear. Risk of
crush injuries if it tips over.
Note: The central gear must not be forced into

place. If there is resistance then the cause must
be investigated.
IMPORTANT! Make sure that the gasket is not

damaged when the central gear is guided in
towards the axle beam. Make sure that the
crown wheel does not get caught at the lower
recess as illustrated.
307 285
7 Place the central gear in position in the axle
housing.
8 Fit every second nut and tighten the nuts
diagonally by hand. Pull in the central gear
with the axle housing surface and gear
housing surface in parallel.
9 Fit the remaining nuts. Tighten the nuts

diagonally to 100 Nm. Then tighten the nuts
diagonally a further 60°.
10 Connect the electrical cables and
compressed air lines to the differential
locks.
20 ©
Reconditioning
11 Push in the half shafts, fit new seals, refit

the drive flanges, and tighten the nuts to
84 Nm.
12 Check the function of the differential locks
and indicator lamps.
13 Fit brake components that were removed as
instructed in the work description under
main group 10.
14 Refit the propeller shafts as instructed in the
work description under main group 6.
Vehicles with connecting member:

• Fit the connecting member (1), shims (4),
and screws (2). Tighten the screws to
135 Nm.
Note: The clearance between the connecting

member and the spring bracket on either side
must not exceed 1 mm. If more than 3 shims are
needed, these should be distributed between
both sides.
• Set the correct drive level as described in

the work description under main group 12
"Bellows heights".
• Tighten the spring bolt nuts to 800 Nm and
further to the next split pin hole. Secure the
nuts with new split pins.
Fill rear axle housing with oil up to lower edge
of level plug.
For the correct oil grade, refer to Workshop
Manual Oils, fluids and lubricants in main
group 0.
08:05-03 ©
Reconditioning
Reconditioning the
differential and renewing
the crown wheel
Tool

87 292 Drift 87 292 R1
87 932 Drift 00 1849 D3, G1
98 120 Lifting hook R2
98 332 Support drift R1
98 450 Shank R2, AD2, AM1
98 566 Drift 98 566 R1

00 1617
98 568 Support drift 98 568 R2

00_1618
22 ©
Reconditioning

98 692 Support drift AD1
98 776 Fixture 98 776 A
110 877
99 136 Hollow drift P
99 147 Drift R3
99 167 Lifting yoke 99 167 G1

00 1625
587 428 Puller XA3

114 056
587 432 Puller plate XA3
08:05-03 ©
Reconditioning
! WARNING!
Use protective goggles when removing

the bearings.
Dismantling
Picture Remarks to illustrations

Place the central gear in a universal stand.
Remove the axle differential lock actuating unit parts.
1 Remove the caps and lift out the differential housing using tool 98 120 or a
round rod with max. 23 mm diameter.
2 Turn the puller plate as shown in illustration, and tighten it so it grips well.
3 Turn the puller plate as shown in illustration, and tighten it so it grips well. There
is a high risk that the bearing will be damaged and will have to be replaced.
4 Mark the differential housing halves together with the differential spider (A).
Before separating the differential housing halves, note that the component parts
of the differential housing must be refitted in their original location during
assembly. Keep parts 1-8 together if they are to be reused.
5 If necessary, mount the crown wheel with the differential housing half in the
press and loosen the nuts with a long tommy bar or a large nut runner.
6 Press out the differential housing half using tools as shown in the illustration.
7 If any of the wear washers needs to be renewed, both washers at pos. 2 and 8 or
all four washers at pos. 6 must be renewed.
24 ©
Reconditioning
08:05-03 ©
Reconditioning
Assembly • Assemble the differential housing with

new oiled screws. Clamp the differential
housing in the press with 20-30 kN.
Tighten the screws diagonally to 90 Nm,
! WARNING! and then diagonally a further 90°.
Use protective goggles when pressing Figures 5 and 6:

as oil may spray up. • Oil the sliding surfaces and press on the
bearing using the tools as shown in the
picture. Begin with the crown wheel side.
IMPORTANT! All parts must be cleaned Check that the bearings are pressed to the
thoroughly before assembly. bottom.
Figure 1:
• Press new screws into the crown wheel.
Figure 2:
• Turn the crown wheel over in the press,
and place the differential housing half on
it. Clamp the crown wheel/differential
housing half in the press with 20-30 kN.
Oil new nuts and tighten them diagonally
until the differential housing half abuts
against the crown wheel. Tighten the nuts
diagonally to 270 Nm and then diagonally
a further 90°.
Figure 3: Differential housing half, new type
with Torx screws.
• Reassemble the component parts of the
differential housing according to the marks
made earlier. Oil all components
thoroughly.
• Assemble the differential housing with
new oiled screws. Clamp the differential
housing in the press with 20-30 kN.
Tighten the screws diagonally to 70 Nm,
and then diagonally to 130 Nm. Finally,
tighten the screws diagonally a further
120°.
Figure 4: Differential housing half, old type
with internal hexagon screws.
• Reassemble the component parts of the
differential housing according to the marks
made earlier. Oil all components
thoroughly.
26 ©
Reconditioning
08:05-03 ©
Reconditioning
Reconditioning the pinion

and pinion bearing
housing, and adjusting the
pinion height
Tool

87 156 Drift AM1
87 408 Drift AM1
87 492 Guide pin M14 R2
87 582 Support drift for puller R2
87 932 Drift G1, D2
28 ©
Reconditioning

98 224 Pressplate G1
98 125 Magnetic disc MV
98 450 Shank R2, AD2, AM1
98 524 Assembly sleeve R1
98 566 Drift 98 566 R1

00 1617
98 575 Support drift 98 575 G2

00 1621
08:05-03 ©
Reconditioning

98 616 Adjustable drift 98 616 AD2, R2
110 806
98 765 Splined socket 98 765 G2
00_1642
99 107 Pinion position template R3
99 136 Hollow drift P
99 138 Support ring P
99 147 Drift R3
99 167 Lifting tool G1
30 ©
Reconditioning

99 190 Drift G4
99 253 Drift R2
587 511 Puller XA3
08:05-03 ©
Reconditioning
Removal and dismantling

1 Loosen the nut, but do not remove it.
2 Remove the screws from the bearing
housing.
Clean the threads in the puller holes using a
pilot tap.
3 Pull out the bearing housing using two
screws in the puller holes.
Tighten the screws alternately until the
bearing housing comes completely away
from the gear housing.
32 ©
Reconditioning
4 Place the bearing housing in a press on

hollow drift 99 136 and support ring 99 138.
Note: Make sure the pinion lands on a soft

surface when it is pressed out.
Remove the nut and press out the pinion.

5 Remove the seal cover.
Place support drift 87 582 on the bearing,
use puller 587 511 and drift 98 575.
Remove the part of the sealing ring
remaining in the seal cover.
Remove the front pinion bearing.
Retain the spacing ring and the shim. These
will be used for basic settings of bearing
preload on assembly.
08:05-03 ©
Reconditioning
6 Cut off the pinion bearing roller cage.
7 Grind a groove in the bearing race using a

grinding wheel with a diameter of less than
60 mm. Make sure the pinion is not
damaged.
8 Weld a few beads on the bearing race using
an electric welder. Protect the pinion from
welding spatter with a wet rag. Cool with a
wet rag after each weld bead. The bearing
race will break through shrinkage after
4-5 welds. Remove the bearing inner race.
Remove any burrs from the bearing seat
using a whetstone.
9 Remove the circlip.
Note: Do not remove the bearing inner race by

welding, as this may impair the hardness of the
bearing journal.
Remove the inner race of the roller bearing

on the pinion journal by grinding an oblique
groove in the race and then splitting it with a
blunt cold chisel.
The parts must be cleaned thoroughly after
grinding.
34 ©
Reconditioning
10 Tap out the front bearing outer race from the

bearing housing.
11 Turn around the bearing housing and tap out

the rear bearing outer race.
08:05-03 ©
Reconditioning
Assembly and adjustment

1 Place the bearing housing on a press bench,
and press in the rear pinion bearing outer
race.
2 Turn around the bearing housing and press
in the front bearing outer race.
36 ©
Reconditioning
3 Press on the rear pinion bearing.
4 Press on the pinion cylindrical bearing inner

race.
Be careful when selecting the hole in the
pressplate.
08:05-03 ©
Reconditioning
IMPORTANT! Lubricate the pinion bearing

with oil. This is essential to ensure bearing
lubrication during the initial operating period.
5 Fit the spacing ring and shim.

Try first with the spacing ring and the
shim(s) that were used previously.
Lift the bearing housing.
6 Lubricate the bearing with oil and press on
the front pinion bearing.
Rotate the bearing housing to and fro while
pressing.
Cease pressing if the bearing housing gets
difficult to rotate. Then, prise apart and fit a
thicker shim or a thicker spacing ring.
38 ©
Reconditioning
7 Increase the press force to 70-80 kN

(7-8 tonnes) while rotating the bearing
housing.
Measure the rolling resistance using a

spring balance and tape wound around the
pinion bearing housing.
Adjust to 80-170 N for new bearings (or
20-40 N for used bearings).
If the resistance is too high, use thicker
shims or spacing ring.
If the resistance is too low, use a thinner
shim or spacing ring.
• Shims are available in the following
thicknesses: 3.00, 3.01, 3.02, 3.03, 3.04,
3.05, 3.06, 3.07, 3.08 and 3.09 mm.
• Spacing rings are available in the following
thicknesses: 10.80, 10.90, 11.00, 11.10,
11.20, 11.30 and 11.40 mm.
8 Apply locking compound 561 029 to the
sealing surface of the seal cover with the
bearing housing and press it into the bearing
housing.
9 Fit a new sealing ring for the end yoke as
described in spot repairs: Renewing sealing
ring on pinion.
Lubricate the splines, centre the end yoke
and press it in place.
If needed, press with 99 190.
Screw on the nut by hand.
08:05-03 ©
Reconditioning
10 Tap out the cylindrical support bearing.
11 Tap in a new support bearing.

12 Fit a circlip against the rollers in the support
bearing. This will press the rollers against
the bearing outer race.
40 ©
Reconditioning
13 Screw in two guide pins diametrically

opposite each other in the gear housing.
Put in place the shims used previously.
Oil the support bearing and lower the
pinion.
Make sure that the support bearing inner
race on the pinion journal enters straight
into the support bearing.
14 Pull down the pinion bearing housing using

two M14x75 screws.
Note: While tightening, make sure the support

bearing inner race on the pinion journal enters
straight into the support bearing.
Tighten both screws simultaneously, and

make sure to keep the A dimension identical
around the circumference to avoid tilting.
Pull down the bearing housing the final part
of the way using the normal screws. Torque
tighten the screws to 135 Nm.
Tighten the pinion nut and secure it according to
spot repair: Renewing sealing ring on pinion.
Keep the circlip which was used to press out the
rollers in the support bearing.
08:05-03 ©
Reconditioning
Adjusting pinion height
1 Check the deviation measurement before

adjusting.
There are two white numbers painted on the
crown wheel between two rivet holes on the
tooth side that indicate the deviation
measurement A in hundredths of a mm, for
example, 65 = 0.65 mm. The setting
dimension for the pinion is (0.5 + A) ± 0.05.
Note: The deviation measurement must not be

confused with the four digit batch number B,
which is different for each individual gear set.
The same number should be found on the pinion
and the crown wheel.
2 Place the magnetic disc 98 125 on the end of

the pinion and the pinion position template
99 107 in the bottom of the differential
bearing seat. Make sure the template is
vertical and parallel with the centre-line of
the differential. Hold down the template so
it does not wobble while measuring.
42 ©
Reconditioning
Adjusting backlash and

bearing preload
Gear set, type Clearance, mm

Ground 0.20-0.30
Other 0.30-0.41
Tool

98 075 Dial gauge 98 075 D2
0
90 10
10 90
80 20
20
80
15 5
30 10
70
70 30
40 60
60 50 40
50
00_1637
587 250 Indicator stand A

102350
Fitting the differential housing

1 Oil the two bearings on the differential housing.
2 Lift the differential housing including the two
bearing outer rings.
3 Fit the two caps.
08:05-03 ©
Reconditioning
Adjusting backlash and bearing

preload
1 Loosely tighten the cap screws. The screw
threads and contact surfaces must be
lubricated.
2 Oil the threads of the two adjusting rings.

3 Screw in the two adjusting rings so that the
bearing races lie loose against the bearings.
4 Then screw in the adjusting ring (A) until
the backlash is zero (if necessary, gradually
screw out the adjusting ring on the other
side). Unscrew the adjusting ring (A) one
turn.
5 Fit indicator stand with dial gauge as
illustrated.
6 Screw in the adjusting ring on the other side
(B) until at least 0.50 mm backlash is
obtained.
7 Then unscrew the adjusting ring (B) one
turn.
Note: Only screw the adjusting ring (A)

inwards. If the clearance is less than the lowest
value, it is necessary to start again from step 6
before the clearance can be reduced again.
8 Screw in the adjusting ring (A) until the

clearance is within the specified tolerance
for that type of gear set. It is better to be
closer to the lower value, because the
clearance can increase slightly when the cap
screws are tightened. Screw in the set screw
so that the tapered point on the set screw
contacts the lugs of the adjusting ring. Then
undo the set screw slightly. Tighten the
adjusting ring on the other side (B) by hand
until it starts to feel tight. Then tighten a
further 2-3 notches to obtain the correct
bearing preload. Screw in the set screw so
that the tapered point on the set screw
contacts the lugs of the adjusting ring. Then
undo the set screw slightly.
44 ©
Reconditioning
9 Move the stand with the dial gauge to one

side. Rotate the crown wheel 5-6 rotations.
Put back the dial gauge and check the
backlash.
10 Tighten both cap screws to 100 Nm.

11 Check that the backlash is still within the
specified values. If the backlash is too great,
undo the cap screws slightly. Unscrew the
adjusting ring B one half turn, and then
screw in the adjusting screw A until the
backlash is correct again. Screw in the set
screw as described in step 8. Then screw in
the adjusting ring B by hand until it starts to
feel tight, and then a further 2-3 notches.
Screw in the set screw as described in
step 8. Then tighten the cap screws again to
100 Nm and check the backlash at four
points. If the clearance is less than the
lowest value, it is necessary to start again
from step 6 before the clearance can be
reduced again.
12 Tighten the cap screws a further 90°, then
check the backlash again and lock the
adjusting rings with the set screws.
Tightening torque - 10 Nm.
08:05-03 ©
Reconditioning
Checking mesh image
IMPORTANT! The mesh image confirms that

the teeth are correctly set. A poor mesh image
can lead to damage to the teeth and noise.
1 Apply a thin film of colour marker on two

adjacent crown wheel teeth. Turn the crown
wheel one half turn and repeat the
procedure.
2 Make sure the colour marker makes contact
with the pinion. Turn the end yoke to and
fro a few times. Brake the crown wheel with
your hand at the same time.
Figure 1:
• Check that the mesh image on the leading
and trailing flanks of the teeth corresponds
to the pictures.
• 1 = correct mesh image on leading flank of
crown wheel, convex side.
• 2 = correct mesh image on trailing flank of
crown wheel, concave side.
Figure 2:
• The mesh image should be in the centre of
the tooth flank when a vertical measurement
from the tooth is carried out. At the same
time the horizontal mesh image should not
be outside the marked areas.
• 1 = driving side
• 2 = trailing flank (brake side)
• A = top of tooth.
46 ©
Reconditioning
Correct mesh image, other gear sets
11
1
1
2 2
1 2 10
2
A10 1 2 20
A
2 1
1 1
A A
2 1
1 1
10
2
308 922
10 10
134 309
08:05-03 ©
Reconditioning
Correct mesh image, ground gear sets
2 2
1 2 10
A
A
2 1
1 1
10
2
308 922
48 ©
Reconditioning
Incorrect mesh image
1 Driving side
2 Trailing flank
The pinion must be adjusted further away from
the centre of the crown wheel (at the same time
the backlash must be retained by adjusting the
crown wheel inwards without changing the
bearing preload).
08:05-03 ©
Reconditioning
Incorrect mesh image
1 Driving side
2 Trailing flank
The pinion must be adjusted closer to the centre
of the crown wheel (at the same time the
backlash must be retained by adjusting the
crown wheel outwards without changing the
bearing preload).
50 ©
Reconditioning
Fitting the axle differential

lock actuating unit parts
and adjusting the
clearance
1 Fit the actuating unit part (1) in the gear

housing with the shims (4) used previously,
but without the O-ring (2). Do not fit the
screws (3) yet.
2 Assemble parts 5-8 and hook the lever (5)
onto the pull rod.
3 Fit the screws (3) and (9) and tighten them.
08:05-03 ©
Reconditioning
4 Check the operation of the mechanism.

Connect compressed air to the cylinder and
check that the clearance between the
coupling halves is 0.1-0.6 mm. The
clearance is adjusted with the shims.
Examples:
Removing one 0.8 mm shim will increase
the clearance by approx. 0.5 mm.
Shims are available in thicknesses of 0.3,
0.5, 0.8 and 2.5 mm.
5 When the clearance is correct, dismantle the
mechanism again. Fit a new oiled O-ring (2)
on the cylinder, and assemble the
mechanism as described previously.
6 Fit the switch and tighten it to 20 Nm.
7 Check the function of the switch. The circuit
should be closed when the differential lock
is engaged.
52 ©
Specifications
Specifications
General
Oil capacity in the rear axle housing 12.5 litres

Oil type Refer to Group 0
Thread seal Part no. 561 019
Locking compound Part no. 561 029
Grease for pneumatic components Part no. 319 308
Sealant (silicone rubber) Part no. 816 064
Sealant Part no. 584 079
08:05-03 ©
Specifications
Tightening torques
Screws for axle differential housing, new type (Torx) 70, 130 Nm + 120°
Screws for axle differential housing, old type (internal hexagon) 90 Nm + 90°
Nuts for crown wheel 270 Nm + 90°
Nut for end yoke on pinion 1,000 Nm
Screws for angle gear bearing cap 100 Nm + 90°
Lock bolts for adjusting rings 10 Nm
Screws for pinion bearing housing 135 Nm
Studs in the rear axle housing 80 Nm
Nuts for studs in the rear axle housing 100 Nm + 60°
Oil plug 100 Nm
Switch 20 Nm
Nut, differential lock piston 20 Nm
Nuts for spring bolts 800 Nm
Screws (M14) for connecting member 135 Nm
Nuts for half shaft flanges 84 Nm
54 ©
Specifications
Setting and check values
Setting dimensions for pinion (A+0.5) +/- 0.05 mm

Pinion rolling resistance at a press force of 70-80 kN (new bearings) 80-170 N
Pinion rolling resistance at a press force of 70-80 kN (old bearings) 20-40 N
Backlash for central gear with a ground gear set 0.20-0.30 mm
Backlash for other gear sets 0.30-0.41 mm
Axial clearance for input shaft 0.01-0.06 mm
Clearance between differential coupling halves 0.10-0.60 mm
Spacing rings and shims

Shims for pinion height:
• 0.25, 0.3 and 0.4 mm.
Shims for pinion bearing preload:
• 3.00, 3.01, 3.02, 3.03, 3.04, 3.05, 3.06, 3.07,
3.08 and 3.09 mm.
Spacing rings for pinion bearing preload:
• 10.80, 10.90, 11.00, 11.10, 11.20, 11.30 and
11.40 mm.
Spacing washers for differential locks:
• 0.3, 0.5, 0.8 and 2.5 mm.
Spacing washers for input shaft clearance:
• 0.2, 0.25, 0.3 and 0.4 mm.
08:05-03 ©

Central Gear R560/660/665: en-GB

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08:05-03

Issue 2.4 en-GB

Central gear R560/660/665

Spot repairs Oil/air leak in differential lock actuating unit .......... 8

Reconditioning Removing and fitting the central gear .................... 14

Specifications General ................................................................... 53

The difference between the R560, R660 and Safety

Exploded view drawing

1 Nut 41 Adjusting ring

Setting press force

Set the press force to 120 kN (12 tonnes) as

Use protective goggles when draining

Help protect our environment. Dispose of excess

Oil/air leak in differential lock

The cover is spring loaded and can fly off

2 Remove the screws (3), tap the cover (4), so that

Numbers in brackets refer to the illustration for

Renewing sealing ring on

Number Denomination Picture Tool board

98 765 Splined socket 98 765

99 003 Hydraulic cylinder H1

99 004 Hydraulic pump H1

99 005-1 Pusher adapter 99 005−1

99 010 Plain bush H1

Number Denomination Picture Tool board

99 012 Threaded spindle 99 012

99 377 Drift 99 377

587 318 Puller XA3

587 319 Puller XA3

IMPORTANT! Never strike the end yoke. Risk

Figures 3a and 3b:

Removing and fitting the

Number Denomination Picture Tool board

98 403 Fixture shaft F1

98 404 End yoke bracket 98 404 F1

98 405 Bracket and fixture beam F1

Number Denomination Picture Tool board

Never work under a vehicle with air

• Take the load off the axle housing before

Use protective goggles when draining

Vehicles with connecting member:

1 Loosen the nuts for the half shaft flanges,

IMPORTANT! Do not tap in the area marked in

2 Remove the nuts, cones and half shaft

7 Undo all nuts except two (one in each upper

Be careful during this procedure. Do not

IMPORTANT! Complete cleaning by grinding

5 Fit the paper gasket on the axle housing by

Be careful during this procedure. Do not

Note: The central gear must not be forced into

IMPORTANT! Make sure that the gasket is not

9 Fit the remaining nuts. Tighten the nuts

11 Push in the half shafts, fit new seals, refit

Vehicles with connecting member:

Note: The clearance between the connecting

• Set the correct drive level as described in

Number Denomination Picture Tool board

87 932 Drift 00 1849 D3, G1