Usage:
Start By:
a. remove front axle housing group (fixed)
b. remove rear axle housing group (oscillating)
NOTE: The axle shaft assemblies used in the front and rear axle housing groups are similar. The removal, disassembly, assembly and installation procedures are the same for both axle groups.
1. Install the axle housing group on Tool (G) in a vertical position as shown.
2. Fasten Tool (A) and a hoist to the rim flange of the axle shaft as shown. Remove twenty six bolts (1) and the washers that hold axle shaft assembly (2) to the differential housing. Carefully remove the axle shaft assembly. The weight of the axle shaft assembly is approximately 295 kg (650 lb).
3. Remove the bottom half of the axle housing group from Tool (G). Install axle shaft assembly (2) on tool (G) with planetary carrier assembly (5) facing up as shown.
NOTE: To completely remove retaining ring (3) from the axle shaft assembly, planetary carrier assembly (5) must be removed and disassembled.
4. Use Tool (B) to remove retaining ring (3) from the groove in the end of the axle shaft (4). Position the retaining ring in the planetary carrier.
5. Fasten Tool (C) and a hoist to planetary carrier assembly (5) as shown. Remove the planetary carrier assembly from the axle shaft housing. The weight of the planetary carrier assembly is approximately 80 kg (175 lb).
- a. Using a hammer and punch, push spring pin (7) all the way into shaft (6).
- b. Remove shaft (6), thrust washers (11) and (8) and planetary gear (10) from the carrier.
- c. Remove bearing (9) from planetary gear (10).
- d. Remove spring pin (7) from shaft (6) with a hammer and punch.
- e. Remove the other two planetary gears (10) from the carrier as in Steps 6a through 6d.
- f. Remove retaining ring (3) from the carrier.
- b. Remove shaft (6), thrust washers (11) and (8) and planetary gear (10) from the carrier.
6. Disassemble planetary carrier assembly (5) as follows:
The axle shaft housing has been removed from the axle shaft for better photo illustration of mounting the axle shaft to Tool (G).
7. Fasten the rim flange of the axle shaft to Tool (G) with suitable size bolts as shown in Photo C42124P1. Installation of the bolt will prevent the axle shaft from turning when bearing nut (12) is removed. Use tooling (D) to remove bearing nut (12) from the axle shaft.
8. Fasten tooling (A) and a hoist to the axle shaft housing as shown. Put slight lifting tension on the axle shaft housing.
NOTE: The bearing cone which is located under bearing nut (12) will be removed at the same time that the axle shaft housing is being removed from the axle shaft.
9. Fasten Tool (E) to the axle shaft housing as shown. Put a hand operated hydraulic jack between Tool (E) and the end of the axle shaft as shown. Operate the hydraulic jack to push the axle shaft housing and inner bearing cone off of the axle shaft. Remove the axle shaft housing and inner bearing cone from the axle shaft. The weight of the axle shaft housing is approximately 105 kg (231 lb).
10. Remove the inner bearing cone from the axle shaft housing.
11. Remove inner bearing cup (13) from the axle shaft housing.
| NOTICE |
|---|
Ring gear (14) will be destroyed when it is removed from the axle shaft housing. |
12. Remove ring gear (14) from the axle shaft housing. Using a torch, cut the ring gear in two places 180° apart. Cut the ring gear at the position of the locating dowels in the axle shaft housing. An alternate method is to make three welds equally spaced around the circumference of the ring gear to cause it to shrink. Remove the three locating dowels for ring gear (14).
13. Remove Duo-Cone seal (15) and outer bearing cup (16) from the opposite end of the axle shaft housing.
14. Remove Duo-Cone seal (18) and outer bearing cone (17) from the axle shaft.
NOTE: The following steps are for the assembly of the axle shaft assemblies.
15. Fasten the rim flange of the axle shaft to Tool (G) with suitable size bolts as shown. Heat outer bearing cone (17) to a maximum temperature of 135°C (275°F), and install the bearing cone on the axle shaft as shown. Be sure the bearing cone is seated against the shoulder on the end of the axle shaft. Allow the bearing cone and shaft to cool.
| NOTICE |
|---|
See, "Assembly And Installation Of Conventional Duo-Cone Seals" in this module. |
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry. After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
16. Use Tool (F) to install the Duo-Cone seal in the end of the axle shaft.
17. Lower the temperature of outer bearing cup (16), and install it in the end of the axle shaft housing as shown. Be sure the bearing cup is seated all the way down in the axle shaft housing.
| NOTICE |
|---|
See, "Assembly And Installation Of Conventional Duo-Cone Seals" in this module. |
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry. After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
18. Use Tool (F) to install the Duo-Cone seal in the end of the axle shaft housing.
19. Lower the temperature of inner bearing cup (13), and install it in the opposite end of the axle shaft housing as shown. Be sure the bearing cup is seated all the way down against the shoulder in the axle shaft housing.
NOTE: Four dowels (19) are used to locate and hold ring gear (14) in position in the axle shaft housing. The four dowels are not equally spaced.
20. Locate the position of the ring gear in relation to the axle shaft housing by aligning the half holes for the four dowel. Put alignment marks on the ring gear and axle shaft housing to ensure correct installation.
21. Lower the temperature of ring gear (14) to a temperature of -38°C (-36°F). Install four dowels (19) in the half holes on the outside diameter of the ring gear. Use an O-ring seal or rubber band to hold the four dowels in position.
22. Using a press, install ring gear (14) in the axle shaft housing. Install the ring gear with the chamfered side down. As the ring gear is being pressed into the axle shaft housing, it will be necessary to tap four dowels (19) down along with the ring gear. After installation, the ring gear should be even or slightly below the machined surface of the axle shaft housing. The four dowels must be flush with the ring gear.
23. Put a thin coat of clean SAE 30 oil on the outer bearing cone on the end of the axle shaft and on the contact surfaces of the Duo-Cone seal on the end of the axle shaft and in the axle shaft housing. Fasten Tool (A) and a hoist to the axle shaft housing as shown. Lower the axle shaft housing on to the axle shaft.
24. Heat inner bearing cone (20) to a maximum temperature of 135°C (275°F). Install the inner bearing cone on the axle shaft with slight end play remaining. After the inner bearing cone cools, lubricate it with clean SAE 30 oil.
| NOTICE |
|---|
The adjusting nut (12) must be installed with side that has the part number facing away from the inner bearing cone (20). |
25. Put clean SAE 30 oil on bearing nut (12). Install bearing nut (12) on the axle shaft. Tighten the nut until only a small amount of end play remains in the axle shaft assembly.
- a. Install a nut and bolt through one of the outer mounting bolt holes in the axle housing.
- b. Install a 203 mm (8 inch) torque wrench on the bolt installed in Step 26a so that it is in line with the center of the axle shaft.
- c. While turning the axle shaft housing with the torque wrench, note the reading on the torque wrench, and calculate the actual seal drag torque with the following formula:
- b. Install a 203 mm (8 inch) torque wrench on the bolt installed in Step 26a so that it is in line with the center of the axle shaft.
26. Measure the torque required (also called "Seal Drag Torque" or SDT) to rotate the axle housing as follows:
Where:
"SDT" is the actual seal drag torque (in N·m)
"C" is the reading on the torque wrench (in N·m)
"B" is the length of the torque wrench (in meters)
"A" is the bolt circle radius of the axle housing in meters and is equal to .229 m (9.0157 inch).
27. While turning the axle housing with the torque wrench, tighten bearing nut (12) until the torque wrench reading calculated with the following formula is reached:
Where:
"C" is the reading on the torque wrench (in N·m)
"B" is the length of the torque wrench (in N·m)
"A" is the bolt circle radius of the axle housing in meters and is equal to .229 m (9.0157 inch).
"T" is the rolling torque specification for axle bearing preload which is 10.4 to 11.6 N·m (92 to 103 lb inch).
"SDT" is the actual seal drag torque (in N·m) form Step 26.
28. Check to be sure there is zero end play in the axle shaft.
29. If the axle bearing preload rolling torque exceeds the specification, back off bearing nut (12) by 1/8 turn, and reseat the bearing against the bearing nut. Perform Step 27 again.
- a. Install retaining ring (3) in the carrier.
- b. Put clean SAE 30 oil on all parts of planetary carrier assembly (5).
- c. Install bearing (9) in planetary gear (10).
- d. Put thrust washers (11) and (8) on each side of planetary gear (10), and install the planetary gear in the carrier.
- e. Install shaft (6) in the carrier. Be sure the spring pin hole in the shaft is in alignment with the spring pin hole in the carrier. Install a new spring pin in the carrier and shaft. Install the spring pin slightly below the outside surface of the carrier.
- f. Install the other two planetary gears in the carrier as in Steps 30a through 30e.
- b. Put clean SAE 30 oil on all parts of planetary carrier assembly (5).
30. Assemble planetary carrier assembly (5) as follows:
31. Fasten Tool (C) and a hoist to planetary carrier assembly (5). Lower the planetary carrier assembly into the axle housing. As the planetary carrier assembly is being lowered into position, align the flat on the hub of the planetary carrier assembly with the flat on bearing nut (12).
32. Use Tool (B) to install retaining ring (3). Check to be sure that the retaining ring is fully seated in the groove in the axle shaft.
33. Remove axle shaft assembly (2) from Tool (G). Reinstall the bottom half of the axle housing group on Tool (G).
34. Put 6V-6640 Sealant on the machined surface of the axle shaft housing and on the intermediate housing assembly. Fasten Tool (A) and a hoist to the rim flange on the axle shaft. Put axle shaft assembly (2) in position on the differential housing. Install twenty six washers and bolts (1) that hold it. Tighten the bolts to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
End By:
a. install rear axle housing group (oscillating)
b. install front axle housing group (fixed)