ServiceManual
FrontAndRearAxles, Recondition
Thisprocedurecoversthereconditionofthefrontand rearaxleassemblieswithoutdifferentiallock.SeeSM KeysheetArea01---002forreconditionofaxleswithdifferentiallock.Forfrontaxleremovalandinstallation procedure,seeSMKeysheetArea01---004.Forrear axleremovalandinstallationprocedure,seeSMKeysheetArea01---029.
SafetyInstructions WARNING
Readandunderstandthefollowingsafety instructionsbeforeattemptingtoperformany ofthetasks.Thesubassembliesareheavy. Removalfromtheaxlehousingcausesthe unittobecomeunstable.Potentialforsevere injuryispresentifallsafetyinstructionsare notstrictlyfollowed.
Note:Eachaxleassemblyweighsapproximately3,000lb(1360kg).Eachaxleassembly includingsteercylindersweighsapproximately 3,140lb(1425kg).
1.Mountaxleassemblyonsupportswiththedifferentialcarrierassemblyfacingup.Securetosupports withC---clampsorsimilarmeans.
2.Whenhandlingsubassemblies,alwayskeepthe loadwellbalanced,andaslevelaspossible.Move slowlyandkeeptheloadundercontrol.Donotattempttohandlesubassemblieswithoutassistance.
3.Whenliftingsubassemblies,useonlyaliftingdevicewhichhasthepropercapacitytohandlethe load.Allriggingusedmustbeingood,sound conditionandbethepropersizeforthejobtobe performed.
4.Failuretofollowtheseinstructionsduringrigging operationsmayresultindamagetoequipmentor injurytopersonnel.
DisassemblyOfTheFrontAndRear SteerAxleAssemblies
Duringthedisassemblyprocess,inspectbothcupand coneofalltaperedrollerbearings.Ifeithercomponent isdamaged,theymustbereplacedasaset.Labeland tagassemblylocationwheneverabearingistoberemoved.
WARNING
Followallmanufacturersrecommendations concerningsolventsandcleaningsolutions. Seriouspersonalinjurymayresultfrom misuseoftheseproducts.
1.Thebreatherandallotheropeningsshouldbe tightlycoveredorclosedtopreventthepossibility ofsolventfromenteringtheassembly.Thoroughly cleantheexterioroftheaxlewithanapproved cleaningsolvent.Allowtoairdry.
Note:Thedisassemblyandassemblyproceduresofbothrightandlefthandwheelend planetaryassembliesareidentical.
2.Ifrequired,removerearsteerindicator. Rearaxle only.
3.Ifrequired,removesteeringcylinders.RefertoSM KeysheetArea01---007forcorrectprocedure. RefertoFigure1.
4.Removecotterpins(45)andcastlenuts(44)from tierodend(48).
5.Usingatierodflaretool,separatetierodend(48) fromsteeringknucklehousing(26)andremovetie rod(46)assembly.
Note:Twotypesoftierodendsareavailable.In eithercasetoaidtheassemblyprocess,count andrecordthenumberofrevolutionsthatare requiredtoremovetierodend(48)fromtierod (46).
6.Removetherodendusingoneofthefollowing stepsasrequired:
a.Loosenlocknut(47)andremovetierodend (48).
b.Loosennut(54)andremovetierodend(48) fromtierod(46).Ifrequired,removenut(54), lockwasher(55),capscrewandwasher(57), andtierodclamp(56)fromtierod(46).
Note:Axlehousing(42)anddifferentialcarrierhousing(109)oilcapacityis40pt(19L). Planetaryhubhousing(36)oilcapacityis8pt (3.75L)each.
7.Removeplugs(20,35,62,65)andbreather(63). Usingasuitablecontainer,drainaxlehousing(42), differentialcarrierhousing(109),andplanetary hubhousing(36)thoroughlybeforedisassembly. Properlystoreordisposeofusedoil.
1.O---rings 2.Shafts 3.ThrustWashers
4.PlanetaryGears
5.ThrustWashers
6.ThrustButton
7.JamNut
8.Locktab
9.AdjustmentNut
10.WheelStuds
11.PlanetaryHub
12.PlanetaryRingGear
13.ThrustWasher
14.SunGear
15.SnapRing
16.ThrustButton
17.Setscrews
18.PlanetaryCarrierHousing 19.Capscrews&Lockwashers 20.Plug 21.Nuts&Lockwashers 22.Spindle 23.Studs 24.Bushing 25.Seal
26.SteeringKnuckleHousing
27.ShimPack
28.Seal
29.UpperKingpinCap 30.Capscrews
31.GreaseFitting
46.TieRod 47.Locknut
48.TieRodEnd
49.GreaseFitting
50.LowerKingpinCap 51.Seal
52.ShimPack
53.Capscrews 54.Nut
55.Lockwasher
56.TieRodClamp
57.Capscrew&Washer
58.Locktab 59.Capscrews
60.ExpansionPlugs
61.Bushings
62.Plug
63.Breather
64.Studs
65.Plug
66.Bushing
67.Seal
68.Capscrews
69.Lockwashers
70.BearingCaps
71.DowelPins
72.Capscrews&Lockwashers
73.DifferentialCasePlainHalf
74.ThrustWasher
75.DifferentialSideGear
76.DifferentialSpider
77.Capscrews
78.Nuts&Lockwashers
79.BearingAdjuster
80.BearingCup
81.BearingCone
82.DifferentialCaseFlangeHalf
83.RingGear
84.ThrustWasher
85.DifferentialSideGear
86.DifferentialPinionGears
87.ThrustWashers
88.ThrustStop
89.Locknut
90.SnapRing
91.Bearing
92.ShimPack
93.Pinion
94.BearingCone
95.BearingSpacer
96.Capscrews&Lockwashers
97.BearingCone
98.InputFlange
99.O---ring
100.Washer
101.Locknut
102.Deflector
103.Seal
104.BearingCup
105.PinionHousing
106.Gasket
107.BearingCup
108.Nuts&Lockwashers
109.DifferentialCarrierHousing
110.BearingAdjuster
111.BearingCup
112.BearingCone 113.CotterPins FrontandRearAxleAssembly,Continued
SM01---002---023.00
CAUTION
Usecarewhiledisassemblingwheelends. Brakeliningscontaminatedwithexcessive amountsofgrease/lubricantscannotbe salvagedorcleaned.
Note:Matchmarktheplanetarycarrierhousing (18)toplanetaryhubhousing(36)forassembly purposes.
8.Removeallbuttwo,sidebysidecapscrewsand lockwashers(19)retainingplanetarycarrierhousing(18)assemblytoplanetaryhubhousing(36).
9.Rotateplanetaryhubhousing(36)assemblyuntil thelasttwocapscrewsandlockwashers(19)are locatedatthetop.Loosenbutdonotremove,the lasttwocapscrewsandlockwashers(19).
10.Installthreecapscrewsandlockwashers(19)into jackholesprovidedinplanetarycarrierhousing (18)andinstalluntilbondisbrokenonjointbetweenplanetarycarrierhousing(18)andtoplanetaryhubhousing(36).Removecapscrewsand lockwashers(19)usedasjacks.
11.Properlysecureanappropriateliftingdevicetothe planetarycarrierhousing(18)assemblyandremovealltheslack.
12.Removeremainingtwocapscrewsand lockwashers(19).
WARNING
Planetaryringgear(12)isnotsecuredtothe planetaryhub(11).Careshouldbetakento preventthisgearfromaccidentallyfallingout whenplanetarycarrierhousing(18)assembly isremoved.Potentialforsevereinjuryis presentifsafetyprecautionsarenot observed.
13.Removeplanetarycarrierhousing(18)subassembly.
14.Removeplanetaryringgear(12).
15. Ifrequired,disassembleplanetarycarrierhousingsubassembly:
a.Removesetscrews(17).
b.Forassemblypurposes,matchmarkshafts(2) toplanetarycarrierhousing(18).
c.Usingashoppress,removeshafts(2)from planetarycarrierhousing(18).
d.Removeo---rings(1)fromshafts(2).
Note:Forassemblypurposes,recordthe positionoftangslocatedonthrustwashers (3,5)toindentsinplanetarycarrierhousing (18).
e.Removethrustwashers(3,5)andplanetary gears(4).
16.Removethrustbuttons(6,16),snapring(15),sun gear(14),andthrustwasher(13).
Note:Someaxleassemblieshaveajamnutand somehavealocktab(58)securedby capscrews(59)usedforsecuringadjustment nut(9).
WARNING
BrakeLiningFiberWarning
Olderbrakeliningsmaycontainasbestos fibers,acancerandlungdiseasehazard. Brakeliningsmanufacturedtodaycontain non--asbestosfibers,whoselong--term effectstohealthareunknown.Usecaution whenhandlingeitherasbestosor non--asbestosmaterialsusedinbrake linings.RefertoOSHAregulationsforproper handlingofthesematerials.MaterialSafety DataSheets(MSDS)regardingbrakelining materialscanbeobtainedfromyourlocal distributor.
CAUTION
Usecarewhiledisassemblingbrakes.Brake liningscontaminatedwithexcessiveamounts ofgrease/lubricantscannotbesalvagedor cleaned.
RefertoFigure2.
17. Removebrakecaliper:
a.Removecapscrews(10),washers(11),andremovebrakecaliperassembly.
18. Disassemblyofbrakecaliper:
Note:Ifshoeandliningassemblies(12)aregoingtobereused,protectthemfrombeingcontaminatedbylubricants,brakefluid,orother contaminants.
a.Removecapscrews(13),plates(14),andshoe andliningassemblies(12).
b.Removeplug(9),cap(8),andpiston(4)from housing(1).
c.Removedustseal(3),backupring(5),ando--rings(6,7).
d.Ifrequired,removebleederscrew(2). RefertoFigure1.
19. Ifrequired,disassembleplanetarycarrierhousingandbrakerotor:
a.Removejamnut(7)andlocktab(8)thatsecure adjustmentnut(9).
b.Properlysecureanappropriateliftingdeviceto theplanetaryhubhousing(36)andbrakerotor (40)assemblyandremovealltheslack.
c.Removeadjustmentnut(9).
d.Installtheappropriatecapscrewsintojack holesprovidedinplanetaryhub(11).Screwin untilbearingcone(33)andplanetaryhub(11) assemblycanberemovedfromplanetaryhub housing(36).Taglocationofbearingcone(33) forassemblypurposes.Removecapscrews usedasjacks.
e.Ifrequired,removebearingcone(33)from planetaryhub(11).
f.Removeplanetaryhubhousing(36)andbrake rotor(40)assembly.
20. Ifrequired,disassembleplanetaryhub housingandbrakerotorsubassembly:
a.Removecapscrewsandlockwashers(41)and brakerotor(40).
b.Taglocationofbearingcone(38)forassembly purposes.Removeseal(39)andbearingcone (38).
c.Iftheymustberemoved,taglocationofbearingcups(34,37)forassemblypurposes.Removebearingcups(34,37)andwheelstuds (10)fromplanetaryhubhousing(36).
21. Ifrequired,removeanddisassemble spindleandsteeringknucklehousing subassemblies:
a.Removenutsandlockwashers(21)and spindle(22)subassemblyfromsteering knucklehousing(26).
b.Removeseal(25).
c.Inspectbushing(24)forwearand/ordamage. Ifitmustberemoved,useashoppressandthe correctsizedrivertoremovebushing(24).
22.Removeaxleshaftassembly(43).
23.Recordmeasurementandlabellocationofshim pack(27).Removecapscrews(30),upperkingpin cap(29),andshimpack(27).Ifrequired,remove greasefitting(31)fromupperkingpincap(29).
24.Properlysecureanappropriateliftingdevicetothe steeringknucklehousing(26)assemblyandremovealltheslack.
25.Recordmeasurementandlabellocationofshim pack(52).Removecapscrews(53),lowerkingpin cap(50),andshimpack(52).Ifrequired,remove greasefitting(49)fromlowerkingpincap(50).
26.Removesteeringknucklehousing(26)fromaxle housing(42).
27.Ifrequired,removestuds(23),capscrewandnut (32),andseals(28,51).
28.Removeseal(67)fromaxlehousing(42).
29.Inspectbushings(61,66)forwearand/ordamage. Replaceifrequired.Useashoppressandthecorrectsizedrivertoremovebushings(61,66)andexpansionplugs(60).
30.Properlysecureanappropriateliftingdevicetothe differentialcarrierhousing(109)subassemblyand removealltheslack.
31.Removenutsandlockwashers(108)securingdifferentialcarrierhousing(109)subassemblytoaxle housing(42).
32.Removedifferentialcarrierhousing(109)subassembly.
33.Ifrequired,removestuds(64)fromaxlehousing (42).
34.Ifdifferentialcarrierhousing(109)subassemblyis tobedisassembled,mountinastandsimilarto standillustratedinFigure3.
35. Ifrequired,disassembledifferential carrierhousingsubassembly:
a.Usingadialindicator,measureandrecordring gear(83)topinion(93)backlashandtotalendplayofdifferentialbearings.
CAUTION
Ifbearingcaps(70)arenotinstalledinthe correctlocations,theboresandthreadswill notmatchthedifferentialcarrierhousing (109).Itwillbedifficulttoassemblethe bearingcaps(70)onthedifferentialcarrier housing(109)anddamagetocomponents mayoccur.Donotforcethebearingcaps(70) intoposition.
b.Forassemblypurposes,matchmarkbearing caps(70)anddifferentialcarrierhousing(109). c.Removecotterpins(113)andloosen capscrews(68)andbearingadjusters (79,110).