Output hubs, internal gears, the differential, the input pinion and three brake versions (Simplex, Servo and BHF) are walked from teardown to reassembly in this 130-page ZF AP-R 715 repair manual for the planetary steering axle, OEM number 5871 419 002. Disassembly and assembly take up the bulk of the book, backed by illustrated tool tables that tie each ZF special tool to the input, differential, output or brake job it serves. Gleason contact-pattern examples show drive and coast sides as they should look, so you can set pinion distance and fit the 100% locking slide before the housing closes. Hold axial clearance at 0.2 mm, and torque the M24 x 1.5 drain and filler plugs to 70 Nm. Guess a shim, and you buy the bevel set twice. Bookmarked and text-searchable, the file also prints cleanly, so the pages can sit on your bench and soak up gear oil.
What's Inside This ZF AP-R 715 Manual
| System | Pages | Key Topics |
|---|---|---|
| Information to the Repair Instructions | 2 | |
| Preface | 3 | |
| General | 4 | |
| Structure of the Service Manual | 5 | Work Safety |
| Lubrication and Maintenance Instructions | 6-7 | Oil Quality, Oil Change, Grease Lubrication Points, Breather, Oil Level Check, Brake Oil |
| Technical Data and Setting | 8 | Axle Arrangement, Differential Types, Oil Filling Volume |
| Examples of Gear-Tooth-Contact Patterns | 9-10 | Gleason Gear-Tooth System, Coast Side, Drive Side, Pinion Distance |
| Lettering of the Type Plate | 11 | Axle Type, Serial Number, Parts List Number |
| Conversion Table | 12 | Length, Mass, Torque |
| Denomination of Standard Dimensions | 13 | Mass, Force, Work |
| Torque Limits for Screws | 14 | Metric ISO-standard Thread, Metric ISO Fine Thread, Friction Coefficient |
| List of Tools for Disassembly and Assembly | 15-21 | Assembly Carriage, Hot-Air Blower, Clamping Fork, Socket Spanner, Adjusting Screws, Puller Tools |
| Illustrated Tool Tables | 22-31 | Input, Differential, Axle Casing, Output, M-Disc Brake, Brake |
| Disassembly of the ZF-Axle | 32-60 | Axle Versions, Standard Version, Hydr. Simplex-Brake, BHF-Brake, Axle Transmission Case, Output |
| Assembly of the ZF-Axle | 61-85 | Differential, Input Pinion, Locking Slide, Hub, Internal Gear, Sun Gear Shaft |
| Axle Equipment with Flange Brake | 86-89 | Hydr. Simplex-Brake, Hydraulic Servo-Brake, BHF-Brake, Brake Lining Wear Measurement, Emergency Towing |
| Hydraulic-Simplex-Brake | 90-99 | Slack Adjuster, Wheel Cylinders, Brake Shoes, Brake Drum, Brake Anchor Plate, Tension Springs |
| Hydraulic-Servo-Brake | 100-130 | Resetting Device, Wheel Cylinders, Brake Shoes, Brake Drum, Piston, Shaft Sealing Ring |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque (M24 x 1,5) for filling- or control screw | 70 Nm | p. 6 |
| Tightening torque (M24 x 1.5) for drain plug | 70 Nm | p. 7 |
| Backlash (Pinion/Crown wheel) | 0.15 ... 0.27 Nm | p. 8 |
| Axial clearance | 0.2 mm | p. 62 |
| Tightening torque (cylindrical screws) | 68 Nm | p. 63 |
| Planetary carrier cylindrical bolt tightening torque | 32 Nm | p. 85 |
| Oil filling volume - Axle casing | 3.5 - 4.0 litres | p. 8 |
| Oil filling volume - per planetary drive | 0.3 - 0.4 litres | p. 8 |
| Oil filling volume - axle transmission case | 1.0 litre | p. 8 |
| Rolling moment - input pinion support | 1.5 - 2.5 Nm | p. 8 |
| Rolling moment - differential support | 1.0 - 4.0 Nm | p. 8 |
| Tightening torque - input flange | 400 Nm | p. 8 |