Usage:
NOTE: The disassembly and assembly photos are of the CS-563 axle. The CP-533 and CS-533 axles are not equipped with brakes.
Start By:
a. remove rear axle assembly
NOTE: Drain the oil from the axle housings.
1. Install Tool (A), chains and a suitable lifting device to the rear axle as shown. The weight of the rear axle is 374 kg (820 lb).
2. Secure the rear axle assembly to Tool (B).
NOTE: Mark all components as to their original location.
3. Remove bolts (1) and nuts (2).
4. Lift axle housing (3) straight up. The weight of the axle housing is 117 kg (260 lb).
5. Shaft lock (4) and gear (5) may stay with the differential housing when axle housing (3) is removed. If so, remove shaft lock (4) and gear (5) at this time. Note the relieved area (X) on the shaft lock, do not install incorrectly.
6. Secure axle housing (3) to Tool (C).
NOTE: If gear (5) did not remain with the differential housing, remove at this time.
7. Remove O-ring (6). Check for wear or damage. Replace if necessary.
8. If shaft lock (4) did not remain with the differential housing, remove at this time.
9. Remove bolt (7) and shaft washer (8).
10. Remove shim (9) and gear carrier assembly (10).
NOTE: The following steps are for the disassembly of the gear carrier assembly.
11. If bearing (23) is to be removed, use Tool (E).
12. Straighten one end of retaining ring (11). Rotate the ring until a gear shaft can be removed.
13. Remove gear shaft (12).
14. Remove planet gear kit (13) as a unit.
NOTE: Slide the planet gear kit out of the carrier slowly and hold the components together with the washers on the top and the bottom of the planet gear or the thirty two needle bearings will fall out of the planet gear kit.
Carrier (10). Shaft (12). Planet Gear (13). Needle Bearings (14). Washers (15). Spacer (16).
NOTE: Spacer (16) is installed between the two sets of needle bearings.
NOTE: There are two sets of needle bearings.
15. Repeat Steps 12 through 14 for the two remaining planet gear kits.
16. Use Tool (A), reposition axle housing (small end up) and secure to Tool (C) as shown.
17. Use a punch or a small pry bar to unstake seal retainer (17).
18. Lift shaft and bolt assembly (18) straight up and out of the axle housing. The weight of the shaft and bolt assembly is approximately 36 kg (80 lb).
19. If seal retainer (24) and bearing (25) have to be removed, use Tool (F).
20. Remove bearing race (19) from the axle housing.
21. Remove bearing race (20) from the opposite side of the axle housing.
22. Install Tool (D) as shown. Remove eight bolts (21). Remove the axle housing from Tool (C) and install the axle housing in a press with the small end up. Use an appropriate size solid rod to press on Tool (D) and remove ring gear (22).
Assemble Axle Housing (Left Side)
1. If ring gear (1) was removed, put Tool (A) in position on the ring gear as shown. Use a press and an appropriate size rod to push on Tool (A) and the ring gear until the gear is seated in its bore. Check the gap between the bottom of the ring gear and the housing with a feeler gauge to make sure the ring gear is seated.
NOTE: Use guides for alignment of the bolt holes when assembling.
2. Install eight bolts (2) that hold ring gear (1) in the housing. Tighten the eight bolts to a torque of 54 to 61 N·m (40 to 45 lb ft).
3. Lower the temperature of bearing race (3). Install in its proper bore.
4. Lower the temperature of bearing race (4). Install in its proper bore.
5. Put a new seal and retainer (6) in position on the axle shaft.
6. Heat bearing (5) to a temperature of 135°C (275°F). Install the bearing on the axle shaft.
7. Attach Tool (B) and a suitable lifting device to axle shaft assembly (7). The weight of the axle shaft is approximately 36 kg (80 lb).
8. Lower axle shaft assembly (7) into small end bore of axle housing (8).
9. Stake the seal retainer around the axle housing.
10. Install shaft (9) in gear (11). Install one level of sixteen needle bearings (12) around shaft (9). Install spacer (10). Install second level of sixteen needle bearings (12) around shaft (9). Install washers (13) on each end of the gear. The washers will hold the needle bearings in place. Remove shaft (9). Install the gear kit in the carrier assembly. Install shaft (9) through the carrier and gear kit assembly.
NOTE: Repeat this procedure for the other two planet gear kits if necessary.
11. Rotate retainer ring (14) into position and bend the ends of the ring down.
12. Heat bearing assembly (15) to a temperature of 135°C (275°F). Install the bearing on carrier (16).
13. Place carrier assembly (16) into position in axle housing (8).
14. Install shim (17), shaft washer (18) and retainer bolt (19). Tighten bolt (19) to a torque of 480 to 600 N·m (350 to 440 lb ft).
Typical Example
15. Put Tool (C) in position on the axle retainer bolt as shown. Lift the axle shaft up and down to obtain bearing end play. Subtract original shim thickness from the reading obtained. Use the correct amount of shim to obtain zero end play.
16. Install shaft lock (20) as shown.
17. Install gear (21).
18. Install O-ring seal (22).
19. Attach Tool (B) to the axle housing. Hold gear (21) (not shown) in position and lower axle housing down into position on the differential housing. The weight of the housing is 117 kg (260 lb).
20. Install eleven bolts (24) and two nuts (23). Tighten the bolts to a torque of 176 to 230 N·m (130 to 170 lb ft). Tighten the nuts to a torque of 104 to 142 N·m (77 to 105 ft lb).
End By:
a. install rear axle assembly