8 - Training Registration System - VDL Bus & Coach

WORKSHOP MANUAL 

Citea CLE / SLE / XLE 

Main group 8 

1121 DD024801


Foreword 

This workshop manual contains all the relevant 

information to help when tracing and solving technical 

problems, when making adjustments and when carrying 

out repair work. 

The book contains diagrams, system descriptions, fault 

finding instructions and work instructions. It also contains 

safety regulations, which must be strictly observed. 

Experienced mechanics 

The technical information and the explanations of the 

repair work stated in this workshop manual have been 

compiled with the utmost care. 

Whilst compiling this workshop manual, it has been 

assumed that the mechanic has the necessary 

experience and has had the required education or 

training to be able to carry out the work in a responsible 

and safe manner. 

Vehicle type 

The information in this manual has been updated until 

the time of printing and only concerns the following 

vehicle series: 

- Citea CLE 120-255/310/360 

- Citea CLE 129-255/310/360 

- Citea CLE 137-310/360 

- Citea CLE 145-310/360 

- Citea SLE 120-255/310 

- Citea SLE 129-255/310 

- Citea XLE 137-310/360 

- Citea XLE 145-310/360 

In this manual, this series of vehicles is referred to as: 

"Citea CLE / SLE / XLE". 

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CONTENTS 

Technical information 

General information...................................... 1-1 

ZF A-132 rear axle .......................................... 1-1 

Tightening torques ....................................... 2-1 

ZF A-132 rear axle .......................................... 2-2 

Lubricants...................................................... 3-1 

ZF A-132 differential ....................................... 3-1 

ZF A-132 wheel hubs...................................... 3-2 

Filling quantities .............................................. 3-3 

Diagnosis 

ZF A-132 rear axle ......................................... 1-1 

Rear axle......................................................... 1-1 

Differential complaints..................................... 1-2 

Safety 

Safety instructions........................................ 1-1 

Special tools 

Special tools.................................................. 1-1 

0 

1 

2 

3 

4 

ZF A-132 rear axle 

General information...................................... 1-1 

Description ...................................................... 1-1 

Overview diagram of the entire differential ..... 1-2 

Overview diagram of the crown gear and 

satellite housing .............................................. 1-4 

Overview diagram of the pinion housing......... 1-5 

General view of the wheel hub........................ 1-6 

Inspection and adjustment .......................... 2-1 

Checking the rear axle for leaks ..................... 2-1 

Checking the rear axle oil level ....................... 2-2 

Inspecting grease-lubricated wheel hubs........ 2-3 

Checking the wheel speed sensor .................. 2-4 

Removal and installation.............................. 3-1 

Removing and installing the complete rear 

axle ................................................................. 3-1 

Removing and installing the rear axle’s 

add-on components ........................................ 3-3 

Removing and installing the rear axle hub...... 3-4 

Cleaning, draining and filling....................... 4-1 

Draining and filling the rear axle’s oil .............. 4-1 

Cleaning/replacing the rear axle bleed valve .. 4-2 

Service manual ZF A-132 ............................. 5-1 

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CONTENTS 

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0 

1 

2 

3 

4 

Disclaimers 

© 1121 VDL Bus & Coach bv, Valkenswaard, 

The Netherlands. 

In the interest of continuous product development VDL 

Bus & Coach reserves the right to change specifications 

or products at any time without prior notice. 

No part of this publication may be reproduced and/or 

published by printing, by photocopying, in digital format 

or in any way whatsoever without the prior consent in 

writing of VDL Bus & Coach. 

This manual shall be governed by and applied in 

accordance with the laws of the Netherlands. 

Any dispute here under shall be referred to the decision 

of the District Court of ’s-Hertogenbosch in the 

Netherlands 

Next remark is relevant if the text has been translated for 

your convenience from the English original into an other 

language. 

A translation, however, can have the consequence that 

differences of interpretation arise with respect to the 

content and meaning of the text. 

In all cases, therefore, the English version of this 

document will be regarded exclusively as the single and 

authentic source to establish the content and the 

meaning of the text in case of a dispute. 

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TECHNICAL INFORMATION 


0 

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General information 

1. GENERAL INFORMATION 

1.1 ZF A-132 REAR AXLE 

0 


Type ZF A-132 

Max. axle load (nominal) 

13,000 kg 

Axle weight (including spring yokes and torque rods) 

Approx. 1000 kg 

Axle reduction 4.70:1 - 5.22:1 

Brakes 

Knorr SN7000 disc brakes 

Rim size (standard rim size) 7.5 x 22.5 

Tyre size (standard tyre size) 275/70 R22.5 

Wheel bearings 

The wheel bearing play is set during manufacture and does not require any further inspection or adjustment. 

Wheel hub 

Before the wheel hub is installed, the following must be 

applied to the axle stub: 

MOLYKOTE DX 

Wheel speed sensor 

Sensor design 

Sensor type 

Wheel speed sensors “S” or “S+” can be recognized by the 

writing on the wheel sensor. They are interchangeable. 

Resistance value 

Air gap between the oil seal/sensor ring and the wheel 

speed sensor 

Signal shape 

Minimum top voltage (Vmin) at 5 km/h a 

Vmax/Vmin ratio 

a. Measured with the diagnosis equipment. 

Inductive sensor 

“S” or “S+” 

1,175 ± 75 Ohm at 20° C 

0.1 - 0.6 mm 

Sine wave 

> 0.3 V 

1.8 

Comment 

At low speeds, wheel speed sensor “S+” gives a higher voltage 

than wheel speed sensor “S”. 

Oil seal/wheel speed sensor ring 

Axial oscillation 

Maximum 0.2 mm 

ILAh0489 

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0 

Lubrication/sealant 

Wheel speed sensor assembly grease Klüber Klüberplex BE 31-512 

Fuchs URETHYN-E2 

Mobil 

Mobilith SHC-220 

Esso 

Unirex N3 

Identification plate 

The identification plate for the ZF A-132 rear axle is located on the 

axle beam and the differential. 

ILAd0144 

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Tightening torques 

2. TIGHTENING TORQUES 

The tightening torques stated in this chapter deviate from the 

standard tightening torques given in the standard tightening 

torques overview. 

The threaded connections which are not stated here must, 

therefore, be tightened to the torque given in the standard 

tightening torques overview. 

If any fixings (attachment nuts and attachment bolts) are 

replaced, it is very important that the new fixings are exactly 

the same length and quality as those being replaced, unless 

stated otherwise. 

0 

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0 

2.1 ZF A-132 REAR AXLE 

2.1.1 REAR AXLE TIGHTENING TORQUES 

ILAd0135 

A Axle shaft attachment bolts 440 Nm 

B Wheel nuts 

- 1st phase 300 Nm 

- 2nd phase 500 Nm 

- 3rd phase 600 ± 15 Nm a 

C Differential oil drain plug 130 Nm 

D Differential oil spill/filler plug 70 Nm 

E Brake caliper holder attachment bolts 270 Nm 

F Differential attachment bolts 385 Nm b 

G Drive shaft attachment bolts 170 Nm 

H Drive flange attachment bolts 1500 Nm 

I Pinion housing attachment bolts 195 Nm 

J. Adjusting screw 150 Nm c 

K. Bleed valve 5.5 Nm 

a. Retighten after 100 km. If new wheel bolts are fitted, retighten again after 500 km. 

b. Attach with new bolts. Apply Loctite 574 to the bolts. 

c. Apply Loctite 574 to a few turns of the screw thread. 

2 - 2 

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2.1.2 REAR AXLE WHEEL HUB TIGHTENING 

TORQUES 

0 

ILAd0136 

A Axle shaft attachment bolts M16 x 1.5 10.9 440 Nm 

B Inner lock nut 850 Nm 

C Outer lock nut 1,200 Nm 

D Brake disc attachment bolts M16 x 1.5 10.9 300 Nm 

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0 

2.1.3 REAR AXLE MOUNTING TIGHTENING TORQUES 

ILAd0132 

A Shock absorber nut/cap nut M16 x 1.5 100 Nm 

B Air bellows attachment bolt M16 10.9 Max. 170 Nm 

C 1 Air bellows air connection M22 x 1.5 Max. 20 Nm 

C 2 Air bellows nut M10 x 10.9 Max. 45 Nm 

D Upper torque rod nut M18 x 2.5 10.9 360 ± 30 Nm 

E Lower torque rod nut M18 x 2.5 10.9 360 ± 30 Nm 

F Stabilizer shackle nut M12 8.8 79 ± 6 Nm 

G Lower torque rod bolt M18 x 1.5 10.9 440 Nm 

H Upper torque rod bolt M18 x 1.5 10.9 440 Nm 

I Stabilizer bracket bolt M16 10.9 300 Nm 

J Level sensor bolt M10 10.9 Max. 12 Nm 

K Axle attachment bolt M27 10.9 1,100 Nm a 

L Stabilizer bolt M16 10.9 274 ± 22 Nm 

a. Evenly tighten the axle attachment bolts in turn in 3 - 4 phases. 

2 - 4 

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Lubricants 

3. LUBRICANTS 

3.1 ZF A-132 DIFFERENTIAL 

0 

The overview of the oil specifications relates to the maintenance 

schedule as stated in the maintenance manual. 

After an axle repair/axle overhaul, replace the oil after 

approximately 5,000 km with the specified oil. 

Explanation of the overview 

V = may be used. 

Oil classification 

Type of rear axle 

12B 12C 12D 12E 

A-132 V V V V 

Type of rear axle Oil type Viscosity Oil class 

A-132 Shell spirax ASX 

Total Dynatrans DA 

Total Transmission LS 

Shell spirax MX 

75W-90 

80W-90 

75W-140 

80W-90 

For an overview of all the oil products that can be used in the 

ZF A-132 rear axle, please refer to the up-to-date ZF lubricant 

list TE-ML 12, which is available from ZF on request. 

Alternatively, see the ZF website (www.ZF.com). 

12B 

12C 

12D 

12E 

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Lubricants 

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0 

3.2 ZF A-132 WHEEL HUBS 

ZF A-132 

Fuchs Renolit LX-PEP2 

Fuchs Renolit LX-N EP2 

Fuchs Renolit LX-NHU 2 

See the ZF lubricant list TE-ML 12, which is available on request 

from ZF. Alternatively, see the ZF website (www.ZF.com). 

The oil specifications overview is related to the liquids and 

lubricants specifications, DW050334xx. 

3 - 2 

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Lubricants 

3.3 FILLING QUANTITIES 

ZF A-132 

Oil 

A-132 axle volume Approx. 16 litres (oil spill plug is decisive) 

Grease 

The wheel hub unit’s wheel bearings are grease-lubricated. 130 - 150 grams (grease volume per hub) 

0 

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Lubricants 

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0 

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DIAGNOSIS 

DIAGNOSIS 

1 

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DIAGNOSIS 

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DIAGNOSIS 


1. ZF A-132 REAR AXLE 

1.1 REAR AXLE 

FAULT: NOISE IN THE REAR AXLE AND DRIVE 

Possible cause 

Remedy 

The oil level is too low 

Top up the oil. 

The oil has the wrong viscosity. 

Drain the oil and fill with the correct oil. 

There is play in the pinion bearing. 

Adjust the play and/or replace the pinion bearing. 

1 

FAULT: OIL LEAK 


Remedy 

Too much oil. 

Drain the oil. 

The oil has the wrong viscosity. 

Drain the oil and fill with the correct oil. 

The oil seal leaks. 

Replace the oil seal. 

The bleed system is blocked. 

Clean or replace the bleed system. 

There is an oil leak between the contact surfaces of the Clean the contact surfaces and apply new sealant. 

differential housing 

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DIAGNOSIS 


8 


1.2 DIFFERENTIAL COMPLAINTS 

1 

FAULT: BROKEN CROWN WHEEL TEETH, AT LEAST TWO TEETH ARE BRITTLE 


Remedy 

Break as a result of a shock load, sudden grip when pulling 

away with spinning wheels. 

Clean the entire differential and check all the components 

for damage. 

Replace all the damaged components. 

FAULT: BROKEN CROWN WHEEL TOOTH, WEAR BRAKE 


Remedy 

Overloading of the differential as a result of a too high 

load. 


for damage. 


FAULT: EXCESSIVE WEAR PATTERNS ON THE TOOTH FLANK'S CONTACT SURFACE WITH THE PINION 

GEAR 


Remedy 

(Starting) wear break on one of the crown wheel teeth. 

Overloading of the differential as a result of load that is 

too heavy. 


for damage. 


FAULT: RATTLING NOISE IN THE DIFFERENTIAL 


Remedy 

Damaged or broken spider with stuck or rubbing satellite 

wheels. Caused by long-lasting, excessive wheel spinning. 


for damage. 


FAULT: THE PIGNON GEAR HAS SHARP, WORN AWAY TEETH OF 

WHICH THE TOPS HAVE BEEN BROKEN OFF 


Remedy 

Using oil which is of the wrong type, but which still cools 

sufficiently. 


for damage. 


FAULT: DARK DISCOLOURATION OF THE PINION GEAR TEETH, POSSIBLY WITH SEIZED BEARINGS 


Remedy 

Insufficient lubrication due to too little oil, the wrong type 

of oil or heavily contaminated oil. 


for damage. 


Use the correct quantity of oil that meets the specifications. 

1 - 2 

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DIAGNOSIS 


FAULT: THE PINION GEAR TEETH HAVE MELTED 


Remedy 

Lack of lubrication. 

It is possible that water has been mixed with the oil. 


for damage. 


If necessary, check how and where water has got into 

the oil. 

1 

FAULT: PARTS OF THE PINION GEAR TEETH HAVE BEEN BROKEN AT THE TOP 


Remedy 

Overloading of the differential. 

Incorrect adjustment of the differential. 


for damage. 


Pay particular attention to the correct pinion gear adjustment. 


Heavy shock load in the driveline. 

FAULT: CRACKS IN THE PINION 

Remedy 


for damage. 


FAULT: PITTING IN THE TOOTH FLANKS OF THE PINION GEAR 


Remedy 

Insufficient or poor lubrication. 


for damage. 


FAULT: WORN SATELLITE WHEEL BEARINGS, HEAVY WEAR ON THE SPIDER 


Remedy 

Too large flat surfaces of the spider scrape off the oil film 

between the spider and the friction bearing. 


for damage. 


FAULT: THE SHAFT OF THE EPICYCLIC GEARING SPLINES HAVE BROKEN 


Remedy 

The planet gear and ring gear have not been checked 

after an axle shaft has broken. 


for damage. 


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DIAGNOSIS 


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1 

1 - 4 

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SAFETY 

SAFETY 

2 

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SAFETY 

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2 

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SAFETY 

Safety instructions 

1. SAFETY INSTRUCTIONS 

Place the vehicle in the unconditional 

kneeling position before raising the 

vehicle. This will deactivate the 

pneumatic suspension system. 

In order to prevent people from starting 

the engine when work is being carried out 

on the vehicle, always disconnect the 

battery’s earth connection. Place a sign 

that reads “DO NOT OPERATE” on the 

dashboard. 

2 

In order to prevent the DTCO-1381 

tachograph from saving an error code, 

the driver's card must be replaced by the 

workshop card before the battery clamp 

and the negative pole are disconnected. 

To prevent damage to electrical 

components, never disconnect the 

battery terminal clamps whilst the engine 

is running. 

Turn off the contact switch and the main 

switch before disconnecting the 

connection between the battery terminal 

and the negative pole. 

Wait at least 80 seconds after turning off 

the contact switch before disconnecting 

the connection between the battery 

terminal clamp and the negative pole. The 

AdBlue lines may become blocked if the 

connection is disconnected too quickly. 

The work described in this maintenance manual may only be 

carried out by trained and competent personnel. 

Always observe the locally applicable legal safety and environmental 

regulations. 

Comply with all the warnings and safety regulations given in 

this maintenance manual. Always read and observe the 

instructions and warnings given on labels and stickers fitted 

to the vehicle’s components. These stickers have been fitted 

for your health and safety. Do not ignore them! 

Wear clean, well-fitting clothing and, if necessary, apply protective 

cream to the body. 

Remain a safe distance from rotating and/or moving components. 

Avoid unnecessary contact with drained oil. Regular contact 

causes skin damage. 

Always use hoisting sheers when working under the vehicle. 

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1 - 1

SAFETY 

Safety instructions 

8 


Depressurize the air, oil, fuel and cooling systems before disconnecting 

or removing any lines, connections or related 

components. Be aware of a residual pressure and unscrew 

the connection a couple of turns to allow any residual pressure 

to escape before removing the connection. 

Only use the specified special tools. 

2 

1 - 2 

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SPECIAL TOOLS 

SPECIAL TOOLS 

3 

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SPECIAL TOOLS 

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SPECIAL TOOLS 

Special tools 

1. SPECIAL TOOLS 

ILAk0015 

3 

A-132 wheel hub wheel bearing outer race assembly tool, ZF 

no. 5870 050 007 

A-132 wheel hub oil seal assembly tool, 

ZF no. 5870 051 053. 

ILAk0016 

A-132 wheel hub nut assembly and disassembly tool, 

ZF no. 5870 401 146. 

ILAk0017. 

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SPECIAL TOOLS 

Special tools 

8 


ILAk0018 

3 

(2x) M16 x 1.5 x 190 

A-132 wheel hub nut assembly and disassembly tool, 

ZF no. 0636 020 213 in combination with ZF no. 5870 401 

146. 

ILAk0019 

A-132 wheel hub unit guide sleeve, 

ZF no. 5870 651 085. 

ILAk0013 

ZF no. 5870 345 071. 

ILAk0020 

A-132 wheel hub assembly and disassembly tool, 

ZF no. 5870 281 043. 

1 - 2 

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SPECIAL TOOLS 

Special tools 

ILAk0012 

ZF no. 5870 260 004. 

3 

ILAk0040 

VDL Bus & Coach no. 40694980. 

ILAk0025 

Wheel hub oil seal disassembly tool 

VDL Bus & Coach no. 40694928 (A), 

VDL Bus & Coach no. 40484899 (B). 

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SPECIAL TOOLS 

Special tools 

8 


3 

1 - 4 

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ZF A-132 REAR AXLE 


4 

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4 

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1. GENERAL INFORMATION 

1.1 DESCRIPTION 

Differential 

The differential’s gear wheels are hypoid gears. 

A single reduction is produced. 

The tooth flank play between the pinion and the crown gear 

is adjusted using shims. 

The top bearing’s pre-tension is adjusted with the aid of 

shims which are placed between the top bearing and the pinion. 

Wheel hub 

The wheel hub has two compact bearings. The compact 

bearings are sealed on both sides by oil seals. 

The retaining ring located between the wheel hubs has a lip 

on one side. This lip falls into the recess in the axle stub. This 

prevents the hub nut from coming loose in the event of a 

problem with the compact bearing. The hub nut must be 

locked by hand. The lock is achieved by hitting one of the 

retaining ring’s lips into the lock nut’s recess. 

The wheel hub's compact bearings are lubricated by grease. 

New grease must be added periodically. 

The correct wheel bearing play is achieved by fitting the hub 

nut in the correct way. 

The axle shaft and brake disc are attached to the wheel hub 

using bolts. 

The wheel speed sensor ring is integrated in the oil seal. The 

wheel speed sensor is fitted directly in the axle beam with the 

aid of a clamping bush. 

4 

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8 


1.2 OVERVIEW DIAGRAM OF THE ENTIRE 

DIFFERENTIAL 

4 

ILAd0191 

1 - 2 

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1. Lock nut 

2. Fork 

3. Dust cap 

4. Oil seal 

5. Bearing 

6. Bolt 

7. Pinion housing 

8. Bearing 

9. Shim 

10. Pinion 

11. Thrust washer 

12. Guide plate 

13. Nut 

14. Adjusting screw 

15. Adjusting nut 

16. Bearing 

17. Bearing cover 

18. Bolt 

19. Circlip 

20. Top bearing 

21. Differential housing 

22. Bearing 

23. Adjusting nut 

24. Locking pin 

25. Bolt 

26. Bolt 

27. Satellite housing half 


29. Satellite 

30. Spider 


32. Satellite 

33. Satellite housing half 

34. Bolt 

35. Crown gear 

36. Pinion bearing 

4 

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1.3 OVERVIEW DIAGRAM OF THE CROWN 

GEAR AND SATELLITE HOUSING 

4 

1. Bolt 

2. Bolt 


4. Satellite 

5. Satellite 


7. Satellite 


9. Crown gear 

10. Satellite housing halves 

ILAd0192 

1 - 4 

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1.4 OVERVIEW DIAGRAM OF THE PINION 

HOUSING 

4 

1. Lock nut 

2. Fork 

3. Dust cap 

4. Oil seal 

5. Bearing 

6. Bolt 

7. Pinion housing 

8. Bearing 

9. Shim 

10. Pinion 


12. Bearing 

13. Circlip 

ILAd0193 

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1.5 GENERAL VIEW OF THE WHEEL HUB 

4 

1. O-ring 

2. Axle stub 

3. Wheel speed sensor cap 

4. Split washer 

5. Allen screw 

6. Brake disc 

7. Split washer 

8. Bolt 

9. Oil seal/sensor ring 

10. Bearing 

11. Hub 

12. Wheel bolt 

13. Bearing 

14. Oil seal 

15. Hub nut 

16. Locking plate 

17. Lock nut 

18. O-ring 

19. Axle shaft 

ILAd0194 

1 - 6 

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Inspection and adjustment 

2. INSPECTION AND ADJUSTMENT 

2.1 CHECKING THE REAR AXLE FOR LEAKS 

To prevent skin damage, avoid 

unnecessary contact with the oil. Note! 

There is a danger of being burnt by hot 

oil. 

Checking the rear axle for leaks 

1. Visually check the entire rear axle for leaks. 

2. If there is a leak, the leak must be repaired and the rear 

axle must be filled to the correct level (see 

4 - 4.1 Draining and filling the rear axle’s oil (4 -1)). 

4 

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2.2 CHECKING THE REAR AXLE OIL LEVEL 

Comment 

Do not check the oil level immediately after a journey. Allow 

the oil to settle and cool down for approximately half an hour. 

Always read the safety data sheet. 

To prevent skin damage, avoid unnecessary 

contact with the drained oil. Note! There is a 

danger of being burnt by hot oil. 

4 

Checking the rear axle oil level 

1. Place the vehicle on a flat, horizontal surface. Check 

whether the vehicle is level both longways and crossways. 

2. Remove the oil spill plug (A) (SW12). 

3. The oil level must reach the edge of the oil spill plug 

opening. If necessary, top up the oil to the required level 

via the hole in the oil spill plug (A). Always use the specified 

oil (see 0 - 3.1 ZF A-132 differential (3 -1)). 

4. After the inspection, refit the oil spill plug (A) with a new 

sealing ring. Tighten the oil spill plug to the specified 

torque (see 0 - 2.1.1 Rear axle tightening 

torques (2 -2)). 

ILAd0137 

2 - 2 

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2.3 INSPECTING GREASE-LUBRICATED 

WHEEL HUBS 

Inspecting grease-lubricated rear wheel hubs for leaks 

1. If serious traces of grease are observed on new or 

recently fitted wheel hubs, then this may indicate excessive 

use of assembly grease. 

2. If the wheel hubs were not recently fitted, serious traces 

of grease may indicate a leak from the oil seal (1) or the 

O-ring (2). Replace the oil seal/O-ring. 

Wheel hub, rear axle 

1 Oil seal 

2 O-ring 

4 

ILAd0021 

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2.4 CHECKING THE WHEEL SPEED 

SENSOR 

Checking the wheel speed sensor 

1. Connect the VDL Bus & Coach diagnosis equipment. 

2. Select the "Wheel speed sensor" function in the ABS/ 

EBS application. 

3. Check the minimum (Vmin) and maximum (Vmax) peak 

voltage of all the wheel speed sensors at a speed of 5 

km/h. Compare the Vmin values with the values given in 

the technical information (see 0-1.General 

information (1 -1)). 

4. Check whether the Vmax/Vmin ratio exceeds the permissible 

ratio (see 0 - 1. General information (1 -1)). 

A visual inspection of the wheel speed 

sensor/sensor ring is only possible when 

the wheel hub has been removed. 

4 

5. If there are deviating measurement results, check the following: 

• The sensor ring (3) for contamination. Pay special 

attention to contamination between the teeth of the 

sensor ring. If necessary, clean the sensor ring. 

• The sensor ring (3) for damage and serious corrosion. 

Even the most minute damage can cause an ABS fault. 

If necessary, replace the combined sensor ring/brake 

disc. 

• Whether the sensor (1) can move in the clamping bush 

(2). If the sensor cannot move, remove the sensor, 

clean it and refit it (see the workshop instructions, 

DW050821). If necessary, replace the clamping bush. 

Never use a hammer to tap the sensor 

into the swivel axle. This may damage 

both the sensor and the sensor ring. 

• The wheel bearing play. 

• The tyre size. 

• The wheel speed sensor wiring. 

• The wheel speed sensor resistance value. 

• The operation of the ABS system. 

ILAh0490 

2 - 4 

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Removal and installation 

3. REMOVAL AND INSTALLATION 

3.1 REMOVING AND INSTALLING THE 

COMPLETE REAR AXLE 

4 

1. ECAS sensor control rod 

2. Stabilizer bracket bolts 

3. Shock absorber cap nut/nut 

4. Shock absorber 

5. Air-spring bellows bolt 

6. Upper torque rods nuts/bolts 

7. Stabilizer rod 

8. Lower torque rods nuts/bolts 

9. ECAS height sensor 

ILAd0161 

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8 


4 

Removing the complete rear axle 

1. Remove the negative clamp from the battery. 

2. Hoist the vehicle and support it at the rear by placing 

hoisting sheers under the chassis (see maintenance 

manual DD021700). 

3. Unscrew the spring brake cylinders’ central bolts as far 

as possible 

4. Disengage the parking brake. 

5. Disconnect the air lines from the spring brake cylinders. 

6. Disconnect the connectors for the brake lining wear indicators 

and the ABS connectors. 

7. Disconnect the ECAS unit's control rods (1). 

8. Remove the drive shaft’s attachment bolts and remove 

the drive shaft (see group 3). 

9. Remove the stabilizer rod (7) by removing the attachment 

bracket (2) (see group 9). 

10. Remove the shock absorbers’ bottom cap nuts/nuts (3). 

11. Remove the upper torque rods’ attachment nuts/bolts 

(6). 

12. Remove the bolts (5) at the bottom of the air-spring bellows. 

13. Remove the lower torque rods’ attachment nuts/bolts (8). 

14. If necessary, roll the rear axle, together with the wheels, 

out from under the vehicle and remove the wheels. 

15. Remove the rear axle’s add-on components (see 

4 - 3.2 Removing and installing the rear axle’s add-on 

components (3 -3)). 

Installing the complete rear axle 

1. Fit the wheels to the rear axle. 

2. Fit the rear axle’s add-on components (see 

4 - 3.2 Removing and installing the rear axle’s add-on 

components (3 -3)). 

3. Roll the rear axle, together with the wheels, under the 

vehicle. 

4. Carry out points 1 to 13 given above (Removing the complete 

rear axle) in the reverse order. For the tightening 

torques, see: 0 - 2.1.1 Rear axle tightening 

torques (2 -2). 

3 - 2 

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3.2 REMOVING AND INSTALLING THE REAR 

AXLE’S ADD-ON COMPONENTS 

Removing the add-on components 

1. Remove the upper and lower torque rods (see group 9). 

2. Remove the spring yokes’ attachment bolts (8). 

3. Remove the spring yokes. They are positioned on the 

axle beam with spring tension pins (6 and 7). 

4 

Installing the add-on components 

1. Fit the upper and lower torque rods (see group 9). 

2. Use the spring tension pins (6 and 7) to position the 

spring yokes against the axle beam. 

3. Use the attachment bolts (8) to fit the spring yokes. 

See 0 - 2.1.3 Rear axle mounting tightening 

torques (2 -4) for the tightening torques. 

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8 


3.3 REMOVING AND INSTALLING THE REAR 

AXLE HUB 

For reference, see the ZF repair manual 

ZF no. 5871 207 002. 

4 

ILAd0035 

Removing the rear wheel hub 

1. Jack up the vehicle according to the instructions (see 

Group 0). 

2. Drain the oil (see 4 - 4.1 Draining and filling the rear 

axle’s oil (4 -1)). 

3. Remove the wheel (see group 7). 

4. Remove the brake caliper and the brake caliper bracket 

from the rear axle (see group 6). 

5. Remove the axle shaft's (1) attachment bolts. 

6. Remove the axle shaft. If necessary, use the special tool 

(VDL Bus & Coach no. 40694980) or a pneumatic hammer. 

A small amount of oil may be released when removing 

the axle shaft. Collect this oil. 

7. Loosen the lock and remove the lock nut (3). 

8. Remove the locking plate (4). 

9. Remove the hub nut (5) using the special tool (ZF no. 

5870 401 146). 

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10. Fit the guide bush (A) (special tool ZF no. 5870 651 085) 

on the axle stub. 

11. Attach hoisting equipment (special tool ZF no. 5870 281 

043) to the wheel hub. 

12. Use the hoisting equipment to slide the wheel hub off the 

axle stub. 

When doing so, make sure the wheel hub does not rest 

on the guide sleeve; it is not able to take the weight of the 

wheel hub. 

13. Place the brake disc side of the wheel hub on a workbench. 

Use a clamp to secure the wheel hub/brake disc. 

14. Remove the attachment bolts (B) from the brake disc and 

remove the wheel hub (8) from the brake disc (13). 

15. Remove the O-ring (11). 

16. Use the special tool (ZF no. 5870 345 071) to remove the 

oil seal (12) on the brake disc side or: 

Drill two holes in the oil seal and screw the special tool 

(VDL Bus & Coach no. 40484899) into the oil seal. Use 

a punch (VDL Bus & Coach no. 40694928) to pull the oil 

seal out of the hub. 

Comment 

Mark the wheel bearings of both hubs. The wheel bearings 

must be reinstalled in their original hub. 

ILAd0036 

4 

17. Remove the locking ring (9). 

18. Remove the wheel bearing inner races (7 and 10). 

19. Remove the grease from the wheel hub and clean the 

wheel hub. 

20. Use a cleaning liquid to thoroughly clean the wheel bearing 

cages. 

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8 


4 

Inspecting the rear wheel hub 

1. Check the hub, the wheel bearings and the inner and 

outer bearing races for wear and damage. If necessary, 

replace them. The wheel bearings and the inner and 

outer races must be replaced as pairs. 

2. Blow the wheel bearing cages dry with compressed air. 

Installing the rear wheel hub 

1. If removed, fit the wheel bearing outer races into the 

wheel hub using the special tool (ZF no. 5870 050 007 

and 5870 260 004). 

2. Lubricate the wheel bearings as indicated using the 

specified wheel bearing grease (see 0 - 3.2 ZF A-132 

wheel hubs (3 -2)). 

Comment 

Apply a thick layer of grease to the inside, outside and front 

of the wheel bearing. 

The total quantity of grease per bearing is 130 - 150 g. 

3. Fit the wheel bearing inner race (10) on the disc brake 

side. In order to ensure that the bearing lays correctly 

against the wheel bearing outer race, push the wheel 

bearing inner race firmly into place and rotate the bearing 

a number of times (roll in). 

Comment 

The wheel bearing inner race on the brake disc side can be 

recognized by the groove for the O-ring (11). 

4. Turn the wheel hub over and place the wheel hub, 

together with the wheel bearing, on an assembly driver 

so that the wheel bearing inner race is supported. 

5. Fit the outer wheel bearing inner race (7) into the wheel 

hub. 

In order to ensure that the bearing lays correctly against 

the wheel bearing outer race, push the wheel bearing 

inner race firmly into place and rotate it a number of times 

(roll in). 

It is essential that the wheel bearing inner races are 

assembled free of play. 

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6. Use the locking ring (9) to connect both wheel bearing 

inner races. Check whether both wheel bearing inner 

races are correctly connected to each other using the reference 

measure 140 ± 0.4 mm. 

7. Use the special tool (ZF no. 5870 051 053) to fit a new oil 

seal (6) in the wheel hub. NOTE: the oil seal should have 

the words "OELSEITE/OILSIDE" facing upwards. 

8. Use the special tool (ZF no. 5870 051 053) to fit a new oil 

seal (12) in the wheel hub on the brake disc side. NOTE: 

the oil seal should have the words "OELSEITE/OILSIDE" 

facing upwards. 

9. Fit a new O-ring (11) in the bearing inner race’s groove. 

10. Fit the brake disc (13) on the wheel hub (8). Tighten the 

attachment bolts to the specified torque (see 

0 - 2.1.2 Rear axle wheel hub tightening 


11. Carefully check the axle stub’s screw thread for damage. 

ILAd0040 

It is not permitted to install a wheel hub to 

an axle stub with a damaged screw 

thread. 

4 

12. Apply a thin, even layer of anti-corrosion agent to the 

axle stub (see 0 - 1. General information (1 -1)). 

Comment 

Do not apply too much anti-corrosion agent to the axle stub. 

When installing the wheel hub, the excess anti-corrosion 

agent will collect at the rear of the wheel hub. 

When using the vehicle, it may flow away and give the 

impression that the oil seal leaks. 

ILAd0041 

13. Fit the guide bush (A) (special tool ZF no. 5870 651 085) 

on the axle stub. 

14. Securely attach the wheel hub to mobile hoisting equipment. 

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8 


4 

15. Use the mobile hoisting equipment to place the wheel 

hub exactly in front of the axle stub. Slide the wheel hub 

on to the axle stub. 

When doing so, make sure the wheel hub does not rest 

on the guide sleeve; it is not able to take the weight of the 

wheel hub. 

16. Fit the hub nut (5). Note the position of the hub nut; the 

camber should point outwards. 

Tighten the hub nut to the specified torque (see 


torques (2 -3)). When tightening the hub nut, rotate 

the hub a couple of turns in both directions. Use the special 

tool (ZF no. 5870 401 146) to do this. 

17. Fit the locking plate (4). Fit the locking plate so that the 

locking lip is on the inside. 

18. Fit the lock nut (3). Note the position of the lock nut; the 

camber should point inwards. 

Tighten the lock nut to the specified torque (see 



Use the special tool (ZF no. 5870 401 146) to do this. 

19. Check again whether the wheel bearings have been 

installed correctly. 

• If the wheel bearing inner race locking ring has been fitted 

correctly, then the axle stub will protrude 1.5 mm 

from the lock nut. 

• If the wheel bearing inner race locking ring has NOT 

been fitted correctly, the axle stub will be flush with the 

lock nut. 

20. Lock the lock nut (3) with the locking plate (4). 

21. Push the wheel speed sensor against the sensor ring. 

The air gap between the sensor and the sensor ring will 

be automatically set whilst driving. 

If the sensor is stuck, remove it, clean it and reinstall it. 

22. Fit the axle shaft (1) with a new O-ring (2). 

Tighten the bolts to the specified torque (see 



23. Fit the brake caliper and the brake caliper bracket (see 

group 6). 

24. Fit the wheel (see group 7). 

25. Check the operation of the ABS system. 

3 - 8 

If, when tightening the hub nut, an 

increase in the wheel bearing roll 

moment is not observed or axial wheel 

bearing play is felt, then it is possible that 

the wheel bearing locking ring has been 

installed incorrectly. 

Never tap the sensor ring with a hammer. 

This may damage both the sensor and 

the sensor ring. 

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26. Fill the rear axle with oil (see 4 - 4.1 Draining and filling 

the rear axle’s oil (4 -1)). 

27. Check the rear axle for leaks. 

4 

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4 

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Cleaning, draining and filling 

4. CLEANING, DRAINING AND FILLING 

4.1 DRAINING AND FILLING THE REAR 

AXLE’S OIL 

To prevent skin damage, avoid unnecessary 

contact with the drained oil. 

Always read the safety data sheet. 

Note! There is a danger of being burnt by hot 

oil. 

Draining the rear axle oil 

1. Place the vehicle on a flat, horizontal surface. 

Check whether the vehicle is level both longways and 

crossways. 

2. Remove the oil spill/filler plug (A) (SW12) and the oil 

drain plug (B) (SW19). Drain the oil, preferably whilst the 

oil is warm. 

3. Clean the oil drain plug. Fit the oil drain plug (B) with a 

new O-ring. Tighten the drain plug to the specified torque 

(see 0 - 2.1.1 Rear axle tightening torques (2 -2)). 

4 

ILAd0137 

Filling the rear axle with oil 

1. Fill the rear axle via the oil spill/filler plug (A) with the 

specified oil (see 0 - 3.1 ZF A-132 differential (3 -1)) 

to the rim of the oil spill/filler plug (approx. 16 litres). 

2. Check the oil level after approximately 5 minutes (see 

4 - 2.2 Checking the rear axle oil level (2 -2)). 

3. Clean the oil spill/filler plug (A). Fit the oil spill/filler plug 

with a new O-ring. Tighten the oil spill/filler plug to the 

specified torque (see 0 - 2.1.1 Rear axle tightening 


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Cleaning, draining and filling 

8 


4.2 CLEANING/REPLACING THE REAR 

AXLE BLEED VALVE 

Cleaning the rear axle bleed valve 

1. Use a suitable cleaning product to clean the bleed opening 

and the bleed valve. 

Replacing the rear axle's bleed valve 

1. Clean the bleed valve (C) and its surrounding area. 

2. Remove the bleed valve from the rear axle. 

3. Fit a new bleed valve to the rear axle. Tighten the bleed 

valve to the specified torque (see 0 - 2.1.1 Rear axle 

tightening torques (2 -2)). 

4. Remove the protective cap from the bleed valve. 

4 

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Service manual ZF A-132 

5. SERVICE MANUAL ZF A-132 

4 

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Service manual ZF A-132 

8 


4 

5 - 2 

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8 - Training Registration System - VDL Bus & Coach

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