Section 3 Prepare Parts for Assembly
Contents
1. Section 3 Prepare Parts for Assembly Output Shafts Inspect output shafts for wear and cracks on the shaft body or in the splines Replace output shaft if required These shafts may be serviced individually as required Repair or Replace Parts Replace the worn or damaged parts of an carrier box assembly The following are some examples to check for repair and possible replacement e Replace any fastener if corners of the head are worn e Replace washers if damaged e Replace oil seals or grease seals at the time of carrier box repair e Clean parts and apply new liquid gasket material where required when the carrier box is assembled e Remove nicks marks and burrs from parts having machined or ground surfaces Use a fine file India stone emery cloth or crocus cloth for this purpose CAUTION Thread must be without damage and clean so that accurate adjustment and correct torque values can be applied to fasteners and parts e Clean and repair the threads of fasteners and holes Use a die or tap of the correct size or a fine file for this purpose e Refer to Torque Table in Section 4 when tightening all fasteners Welding Repair The carrier box assembly housing material is Not suitable for welding repair Do not attempt to repair weld this carrier box assembly Removing Dri Loc Fasteners If it is difficult to remove fasteners from components the strength of Dri Loc adhesive or Loctit2. Even when exposures are expected to be within the maximum allowable levels wearing such a respirator at all times during brake servicing will help minimize exposure 3 Procedures for Servicing Brakes a Enclose the brake assembly within a negative pressure enclosure The enclosure should be equipped with a HEPA vacuum and worker arm sleeves With the enclosure in place use the HEPA vacuum to loosen and vacuum residue from the brake parts b As an alternative procedure use a catch basin with water and a biodegradable non phosphate water based detergent to wash the brake drum or rotor and other brake parts The solution should be applied with low pressure to prevent dust from becoming airborne Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the brake parts clean with a cloth c If an enclosed vacuum system or brake washing equipment is not available carefully clean the brake parts in the open air Wet the parts with a solution applied with a pump spray bottle that creates a fine mist Use a solution containing water and if available a biodegradable non phosphate water based detergent The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the br
3. Figure 3 2 E e Deep cracks or breaks in the cup cone inner race or roller surfaces Page 10 AxleTech International Pinions and Gears A CAUTION Spiral bevel pinion and gear are machined ina matched set When a pinion or ring gear of a set needs to be replaced both the gear and pinion must be replaced at the same time 1 Inspect the bevel drive pinions and ring gears for wear and damage Gears that are worn or damaged must be replaced 2 Verify the condition of the bearing cone seats and spline on the pinion shaft Main Differential Assembly A CAUTION Always replace thrust washers differential side gears and pinion gears in full matched sets A higher stress on original parts and early failure of the entire assembly will result if a new part is used in combination with parts that are older or worn Inspect the main differential assembly Parts that are damaged must be replaced Inspect the following parts for wear or stress Figure 3 5 e Inside surfaces of both case halves e Both surfaces of all thrust washers e Trunnion ends of the spider cross or differential pinion shaft e Teeth splines and thrust surface of differential side gears e Teeth bore and thrust surface of differential pinions Figure 3 5 4 PINION DIFFERENTIAL NEST ASSEMBLY SIDE GEAR AND PINION AND THRUST WASHER THRUST c DIFFERENTIAL WASHER CASE HALF Inspect inside surfaces N TN SPIDER Ps US CROSS
4. AxleTech International Installing the Drive Pinion 1 Apply the specified lubricant to the pinion bearings and cups Refer to Section 5 NO Insert pinion into carrier housing P2 Versions with oil seal only Install pinion oil seal flush with face of pinion cage 4 Apply lubricant to O D of pinion bearing cage and O ring if there is one 5 Set pinion bearing preload by threading cage into carrier housing and verifying that cage lock plate matches one of the four possible positions 6 Use a small Ib in torque wrench at input yoke or else attach a spring scale to the U joint yoke or clamping device Rotate the drive pinion by pulling the spring scale Observe the scale movement Figure 4 3 Figure 4 3 N If the preload measurement does not equal 5 20 Ib in 5 8 23 kgf cm Adjust the preload by rotating the drive pinion bearing cage as necessary 8 Record the pinion bearing preload measurement Refer to the measurement when you set the differential case bearing preload 9 Hold the pinion cage lock plate with bolts Apply thread compound and tighten Refer to the Torque Table in Section 4 ap 10 Apply RTV sealant inside yoke counterbore at bearing end of yoke spline Then assemble yoke onto shaft spline and wipe excess RTV off of yoke s surface where washer and locknut will assemble on threaded shaft 11 Apply thread compound on flanged locknut threads hold yoke with yoke bar and tor
5. Remove all the oil grease dirt and moisture without damaging the mating surfaces 3 Dry both surfaces CAUTION The amount of silicone gasket material applied must not exceed 3 mm 0 125 inch diameter bead Too much gasket material can block lubrication passages and result in damage to the components 4 Apply 3 mm 0 125 inch maximum diameter contin uous bead of the silicone material at the carrier pilot diameter Keep bead far away from bolt holes to prevent sealant from getting in between mating threads during bolt installation This could signifi cantly reduce the effectiveness of the thread locking compound Figure 3 6 5 Assemble the components immediately to permit the silicone gasket material to compress evenly between parts Tighten the fasteners to the specified torque Refer to the Torque Table in Section 4 of this manual 6 Wait 20 minutes before filling the assembly with lubricant AxleTech International 3 MM 0 125 MAXIMUM DIAMETER SILICONE GASKET MATERIAL BEAD Section 3 Prepare Parts for Assembly Figure 3 7 ALTERNATE LOCATIONS 1 2 3 4 Flush Lube From the Carrier Box The carrier box assembly contains its own oil 1 Remove the magnetic oil drain plug and clean all debris from the magnet before re assembly in the carrier box housing 2 The oil fill plug is not magnetic 3 Flush all lubricant from the entire carrier box housing before you re assemble the carrier
6. serious personal injury Follow the manufacturer s instructions to prevent irritations to the eyes and skin 1 Clean the oil and dirt and old adhesive for all threads and threaded holes Use a wire brush 2 Refer to Torque Table to select correct thread compounds 3 Apply four or five drops of liquid adhesive inside each threaded hole CAUTION Do not apply adhesive directly to the fastener threads in blind holes Air pressure will build up and push the adhesive out and away from mat ing surfaces as the fastener is installed 4 Refer to Torque Table in Section 4 and tighten the fasteners to the specified torque T Page 12 AxleTech International Apply Liquid Gasket Material WARNING Take care when you use adhesives thread locking compounds or any sealants to avoid serious personal injury Follow the manufacturer s instructions to prevent irritations to the eyes and skin WARNING Take care when you use silicone gasket materials to avoid serious personal injury Follow the manufacturer s instructions to prevent irritation to the eyes and skin AxleTech recommends the following liquid gasket materials e Three Bond Liquid Gasket No TB 1216 Grey e Loctite Ultra Grey Adhesive Sealant 18581 e From AxleTech Ten ounce tubes Part No 2297 F 7052 1 Remove all the old gasket material from both surfaces 2 Clean the surfaces where the silicone gasket material will be applied
7. above the output yokes on the carrier box assembly 2 Unscrew counter clockwise the output ball bearing cage that retains the shaft assembly on each assembly Section 2 Disassembly 3 Remove as a sub assembly the output yoke yoke lock nut bearing cage output shaft ball bearing and O ring and set on the work bench NOTE The lock nut was assembled with a thread lock applied to the M24x1 5 nut threads 4 To remove the yoke lock nut set the assembly in a vise to restrain the yoke ears Use wrench to loosen lock nut An optional method to remove the yoke lock nut is to use a yoke bar This procedure and yoke bar tool description is shown in the tool section of this manual Remove the yoke from the shaft assembly Remove the bearing cage oil seal O ring from the output shaft assembly and set aside for later cleaning inspection and reassembly A WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury NOTE Care should be taken not to press on the ball bearing outer journal as damage to bearing could occur 7 Remove the ball bearing from the output shaft by placing these components vertically in a hydraulic press and use a Suitable tube cylinder of correct diameter to touch the inner bearing race only to allow the bearing to be pressed off the output shaft Prior to actually pressing the bearing recommend a suitable container be place
8. bearing cage saddle Carefully remove the differential case and ring gear assem bly and set on the work bench Figure 2 6 Figure 2 6 7 RE 1 1 To remove the inner bearing cup from the carrier housing and the outer bearing cup from the pinion bearing cage Use a press and sleeve or a small drift and brass hammer to remove the bearing cup Do not damage the ring journals when you remove the bearing cup Page 7 Section 2 Axl eTech Disassembly International Disassembly of the Differential Cases WARNING Use a rawhide or brass mallet for assembly and disassembly procedures Do not hit steel parts with a steel hammer Pieces of a part can break Continued disassembly of the differential nest com ponents should that be required is done as follows 1 Make alignment marks from the ring gear to the off and cause serious personal injury case halves Figure 2 7 3 Inspect the spiral bevel ring gear for damage If removal of the ring gear is required separate the Figure 2 ring gear from the differential case half with a brass hammer ALIGNMENT MARKS 2 Remove the capscrews that retain the 2 differ ential case halves and remove the components inside the assembly These components include the differential spider 4 planet pinions and washers 2 side gears and washers Figure 2 8 Figure 2 8 4 PINION DIFFERENTIAL NEST ASSEMBLY SIDE GEAR AND PINION AND THRUST WASHER THRUST DIFFERENTIAL WASHER
9. box assembly Gearset Information Drive Pinion and Ring Gear Marks Read the following before installing a new gearset in the carrier Always inspect the gearset for correct marks to make sure the gears are a matched set The locations of the gearset marks are shown in Figure 3 7 1 Part Number a Examples of gearset part numbers e Conventional ring gear 881151002 e Conventional drive pinion 881101002E b Location on Drive Pinion Shaft end c Location on Ring Gear Front face or outer diameter 2 Tooth Combination Number a Example of a tooth combination number 12 35 NOTE An 12 35 gearset has an 12 tooth drive pinion and a 35 tooth ring gear b Location on Drive Pinion Shaft end c Location on Ring Gear Front face or outer diameter 3 Gearset Match Code AxleTech drive pinions and ring gears are available as matched sets Both gears of a set have a match code a Example of gearset match code M29 NOTE A gearset match code has any combination of a number or letter and number b Location on Drive Pinion End of gear head c Location on Ring Gear Front face or outer diameter 4 Pinion Cone Variation Number NOTE The pinion cone variation number is not used when checking for a matched gearset The number is used when you adjust the depth of the pinion in the carrier a Examples Pinion cone variation numbers e PC 3 e 2 e 0 01 mm e PC 5 e 1 e 0 02 mm b Location on Gearse
10. drive pinion teeth Note When you adjust backlash move the ring gear ONLY DO NOT move the drive pinion 5 If the backlash reading is within specification continue checking tooth contact patterns Otherwise adjust backlash Refer to Step 6 and check following Steps 1 4 Page 19 Section 5 Adjustments Note Backlash is increased by moving the ring gear away from the drive pinion Backlash is decreased by moving the ring gear toward the drive pinion Refer to Figure 5 3 and Figure 5 4 6 Loosen one bearing adjusting ring one notch then tighten the opposite ring the same amount Refer to Figure 5 3 and Figure 5 4 Tighten adjusting ring this side Es Increase backlash Loosen adjusting ring this side Loosen adjusting ring this side Tighten adjusting ring this side Page 20 AxleTech International Adjusting Tooth Contact Pattern of the Gearset Always check tooth contact pattern on the drive side of the gear teeth Figure 5 5 1 Apply marking compound to approximately 12 teeth of the ring gear Figure 5 6 DRIVE SIDE CONVEX AxleTech International 2 Rotate ring gear forward and backward so that the 12 marked teeth go past the drive pinion six times to get a good contact pattern 3 Compare the contact patterns to Figure 5 7 Figure 5 8 and Figure 5 9 GOOD HAND ROLLED PATTERN HIGH PATTERN Section 5 Adjustments LOW PATTERN In new gearsets a good contact pattern i
11. maximum to aid assembly Figure 4 2 until the cone is flat against the gear head 5 Install and center the required selective shim pack on the pinion spigot If you install a new bevel gearset ruin 7 Set axial position of drive pinion by installing a selective shim pack between pinion and inner bearing cone Combine basic shims according to the table below Shim pack thickness is correct if gearset tooth contact pattern comes out good Refer to Section 5 Shim Pack Thickness mm 0 2 0 3 0 4 0 5 0 6 Number of 0 2thick 1 2 14 Basic shims 0 3 thick p fap faf2 Assembling the Differential Case aes Bunn 1 Apply the specified lubricant to all parts of 7 Install the differential case to ring gear capscrews differential case assembly before installation Apply thread compound and alternately tighten 2 Press the bearing cones on both differential case Refer to the Torque Table in Section 4 halves 8 Use a 0 025 mm 0 001 inch thick feeler gauge to 3 Install the thrust washer and side gear in each measure the gear bore to differential case pilot case half Insert washer tab in one of the clearance Feeler should not go in more than lubrication openings of the case three places and arc length should not exceed 25 mm 1 inch in each place 9 Use a feeler gauge to measure the gear backface to differential case flange clearance The clear ance must not exceed 0 08 mm 0 003 inch Page 14
12. must be washed with water until the alkaline solution is removed Clean The Carrier Box Housing e The carrier box assembly can be steam cleaned on the outside to remove dirt grease or external contamination e Before the carrier box assembly is steam cleaned close or put a cover over the breather on top of the carrier box assembly NOTE Do not direct steam cleaning spray directly at the carrier input or output yokes amp seal assemblies during the initial cleaning as could attempt to push external dirt into the carrier box assembly components e Remove all metallic particles from the magnetic drain plug Section 3 Prepare Parts for Assembly Dry Cleaned Parts e Dry the parts immediately after cleaning and washing e Dry the parts with soft clean paper or rags caution Damage to bearing can be caused if dried by rotating with compressed air e Except for bearings parts can be dried with compressed air Preventing Corrosion e Apply a light lubricant to cleaned and dried parts that are not damaged and are to be assembled e Apply a special material that prevents corrosion to all surfaces If parts are to be stored wrap the parts in special paper that prevents corrosion Inspecting Parts It is very important to inspect all parts carefully and completely before the carrier and carrier box assembly is assembled Check all parts for wear and replace damaged parts Replacement of damaged or worn parts wil
13. result from inhaling asbestos dust OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels DANGER ASBESTOS CANCER AND LUNG DISEASE HAZARD AUTHORIZED PERSONNEL ONLY RESPIRATORS AND PROTECTIVE CLOTHING ARE REQUIRED IN THIS AREA 2 Respiratory Protection Wear a respirator equipped with a high efficiency HEPA filter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes beginning with the removal of the wheels 3 Procedures for Servicing Brakes a Enclose the brake assembly within a negative pressure enclosure The enclosure should be equipped with a HEPA vacuum and worker arm sleeves With the enclosure in place use the HEPA vacuum to loosen and vacuum residue from the brake parts b As an alternative procedure use a catch basin with water and a biodegradable non phosphate water based detergent to wash the brake drum or rotor and other brake parts The solution should be applied with low pressure to prevent dust from becoming airborne Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed Wipe the brake parts clean with a cloth c Ifan enclosed vacuum system or brake washing equipment is not available employers may adopt their own writ
14. service instructions should be followed when servicing these components under the vehicle NOTE Any pre cleaning on vehicle to remove dirt grease or corrosive material should be per vehi cle manufacturer recommendations Care should be taken to cover the carrier box breather to limit addi tional contamination during pre cleaning process 1 Remove the drain plug 3 4 14 to drain the lubricant into a suitable container Note amount of metal on the magnetic drain plug and clean drain plug 2 Discard the drained lubricant in an environmen tally responsible manner according to state and or EPA recommendations 3 Disconnect the vehicle propshaft from the carrier box input yoke and both output yoke prop shafts from each chain case assembly input yoke per vehicle manufacturer recommendations Care should be taken so personal injury does not occur 4 Support the carrier box assembly for safe removal from the vehicle chassis frame 5 Remove the carrier box assembly from the vehicle per vehicle manufacturer recommended procedures and place on adequate work bench to prepare for disassembly Carrier Box Assembly Disassembly Initial disassembly required for carrier assembly removal for inspection or service requires the removal of the 2 output shafts assemblies Each output shaft assembly may be removed as a total subassembly 1 To remove each output shaft assembly remove the 2 M6x1 0 capscrews and lock tab located
15. to flow through the entire carrier box assembly Check the oil level and fill to the correct level if necessary NOTE Too low an oil level could cause component damage as proper lubrication may not be available to protect against component damage 3 Install and tighten the fill plug to the correct torque specification Carrier Box Oil Recommendations Off Highway Operation Intervals Recommended Check Petroleum Initial Oil Change Oil Level Oil Change 200 Operating hrs Typical 1 000 hrs or once a year whichever comes first The interval depends on the individual operating conditions speeds and loads Severe operating or prolonged use of corrosive materials may require more frequent intervals Approved Oil Listings AGCO Permatran 821XL Transmission and Hydraulic Oil 10W30 or equivalent Mobil 424 Specific oils other than those listed should have approval prior use in this assembly as damage may occur to components in carrier box assembly Approved Grease Recommendations for Carrier Box Assembly Grease Multipurpose Grease 1 50 Operating hrs Specification Per ArvinMeritor grease specification O 617 A NLGI Grade 1 for Lithium 12 Hydroxy Stearate or Lithium Complex 1 AxleTech recognizes that industry trends are moving towards selection and usage of synthetic based greases in vehicle maintenance However some seals are known to expand when in contact with synthetic grease The original assembl
16. AxleTech International Carrier Box Assembly Ensemble de carter de nej de pont Maintenance Manual MM5 3 Issued 6 04 Manuel de maintenance MMS5 3 Edit Mai 04 Models Modeles A4 3200E 2033 293 A4 3200E 2033 292 Service Notes Before You Begin This manual provides instructions for Axle Tech International s Carrier Box Assembly Before you begin procedures 1 Read and understand all instructions and procedures before you begin to service components 2 Read and observe all Caution and Warning safety alerts that precede instructions or procedures you will perform These alerts help to avoid damage to components serious personal injury or both 3 Follow your company s maintenance and service installation and diagnostics guidelines 4 Use special tools when required to help avoid serious personal injury and damage to components Safety Alerts Torque Symbol and Notes A WARNING A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury A CAUTION A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components The torque symbol alerts you to tighten fasteners to a specified torque value NOTE A Note provides information or suggestions that help you correctly service a component The instructions contained in this Field Maintenance Manual are intended for use by skilled and expe
17. CASE HALF Inspect inside surfaces Pasa V OMN SPIDER inspec HO CROSS Page 8 AxleTech International Clean Ground or Polished Parts WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Solvent cleaners can be flammable poisonous and cause burns Examples of solvent cleaners are carbon tetrachloride emulsion type cleaners and petroleum based cleaners To avoid serious personal injury when you use solvent cleaners you must carefully follow the manufacturer s product instructions and these procedures e Wear safe eye protection e Wear clothing that protects your skin Work in a well ventilated area Do not use gasoline or solvents that contain gasoline Gasoline can explode You must use hot solution tanks or alkaline solutions correctly Follow the manufacturer s instructions carefully e Use a cleaning solvent kerosene or diesel fuel to clean ground or polished parts or surfaces NEVER USE GASOLINE e Remove gasket material from parts Take care not to damage ground surfaces e DO NOT clean ground or polished parts in a hot solution tank water steam or alkaline solution Clean Parts with a Rough Finish e Parts with a rough finish can be cleaned with cleaning solvent or in a hot solution tank with a weak alkaline solution e Parts must remain in hot solution tanks until completely cleaned and heated e Parts
18. Cleaned PAS en eee ee tn D eo le 9 PEYR OSU Ice dc ccm tea ce tee tote hater nasties ie i 9 DAS SC TING IP LES PP P E E S A N A nnn 9 Cleaning The Breather asc a dent ou en De em ne ee me ma cie 9 Tapered Roller Be AIG S scere a aucune avian ae aR 10 EU ONS ANd CM a ed AAE EE ne ee D me ae en a 11 Main Diierontal AsSsSembIy See anna SO OEE EERE g 11 OU SAS On 11 RED AIF Or Replace PASS en eee ee ee a ae eme ee ee coment 11 Wada ROPA eee an e ann tee AR na en ne re Ce te AR re dou 11 Removing Dr LOC FASO den aan catho ou aide bind 11 Installing Fasteners With Pre Applied Adhesive VV 12 installing Original Or Used Fasteners 8 ji 12 Apply Liquid Gasket Malaises cabane en mo esse pn ion cree m non cette 12 Flush Lube From The Carrier BOX ne ane an tee eee een ee eee 13 Gearset Information Drive Pinion And Ring Gear Marks 13 Section 4 Assembly Assembling the Pinion Bearing Cage ccccccssscecceseeeceseeeceseecceseeeceuececeeeessaueessageessaaseessseessusseessageesseas 14 Assembling the Differential CAS es men as sn eu 14 Installing the Drive PINIONS sei udenconinincanensanunanlahcnneeaansddusnesagvanpddanalildnadaesaldwandearh ieansceanatedvecsaeanageunsasaaeddnnnds 15 Installing the Differential Case Assembly se 15 Carrier Bearing ad RS 072 0 gt eae nee ee oc ea eee eee ere ne era eee a eee ee 16 installing Carrier Assembly Into Carrier BOX c ccccscnescdiscccdsacnncsaenlsunaibietenadedsuetauneicesoellnesiedcasiande
19. ad the dial indicator The runout must not exceed 0 20 mm 0 008 inch Figure 5 1 INDICATOR Figure 5 1 Rotate ring gear If runout exceeds specifications remove the differen tial and ring gear assembly from the carrier Refer to Carrier Disassembly Procedures and Disassembly of Differential Cases in Section 2 5 Check the differential parts including the carrier for problems that may cause the ring gear runout to exceed specifications Repair or replace parts 6 Re install the differential and ring gear into the carrier Refer to Assembling the Differential Case in Section 4 of this manual 7 Repeat the preload adjustment of the differential bearings Section 5 Adjustments Adjusting the Gearset Backlash Backlash specification 0 13 0 18 mm 0 005 0 007 inch If the old gearset is installed adjust the backlash to the setting that was measured before the carrier was disassembled If a new gearset is installed adjust the backlash to the correct specification for new gearsets 1 Attach a dial indicator on the mounting flange of the carrier Figure 5 2 2 Adjust the dial indicator so that the plunger or pointer is against the tooth surface near the heel end of the gear tooth Set the indicator dial to zero 0 Figure 5 2 7 K 5 3 Hold the drive pinion in position 4 Read the dial indicator while rotating the ring gear a small amount in both directions against the
20. ake parts clean with a cloth d Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or machining brake linings In addition do such work in an area with a local exhaust ventilation system equipped with a HEPA filter e NEVER use compressed air by itself dry brushing or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies NEVER use carcinogenic solvents flammable solvents or solvents that can damage brake components as wetting agents 4 Cleaning Work Areas Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping NEVER use compressed air or dry sweeping to clean work areas When you empty vacuum cleaners and handle used rags wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA to minimize exposure When you replace a HEPA filter wet the filter with a fine mist of water and dispose of the used filter with care 5 Worker Clean Up After servicing brakes wash your hands before you eat drink or smoke Shower after work Do not wear work clothes home Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn Launder them separately Do not shake or use compressed air to remove dust from work clothes 6 Waste Disposal Dispose of discarded linings used rags cloths and HEPA filters with care such as in sealed plastic bags Consult applicable EPA state and local regulations on waste disposal Regulatory Gu
21. bly as shown in Figure 1 1 Description AxleTech International carrier box assembly incorpo rates a single reduction spiral bevel gearing carrier assembly mounted in a carrier box housing for remote drive axle assembly Figure 1 2 The AxleTech carrier box assembly permit the output shafts to carry torsional and axial loads e Power is transmitted by the Spiral Bevel gear set in the carrier to the output shafts e The power is then transmitted into associated Chaincases with planetary hub reductions for final vehicle drive Figure 1 2 CROSS SECTION OF CARRIER BOX ASSEMBLY Pinion Cage Spiral Bevel Pinion Page 4 AxleTech International Figure 1 1 CARRIER BOX ASSEMBLY IDENTIFICATION TAG LOCATION AxleTech movEL A43200E2033292 O CUST No SERIAL No RATIO 2 92 1 0 Spiral Bevel Gear Carrier Box Ball Bearing Output Seal Output Shaft Output Yoke Lock Nut Output Yoke Output Ball Bearing Cage Input Seal LS Input Yoke AxleTech International Disassembly From Vehicle A WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury and damage to components can result OEM
22. box threaded bores until cages bottom solidly against outer race of ball bearings Section 4 Assembly 8 Install cage locks in one of four possible positions in cage lugs at threaded mounting holes by minimiz ing cage rotation to align locks with threaded holes Hold cage lock with bolts apply thread compound and tighten per Torque Table in Section 4 T 9 Install yoke on output shafts by applying RTV sealant inside ounter bore at bearing end of yoke spline Then assemble yoke onto shaft spline and wipe excess RTV off of yoke s surface where washer and locknut will assemble on threaded shaft 10 Apply Loctite to M24 X 1 5 Nut threads not to shaft threads and tighten per Torque Table in Section 4 ap 11 Apply sealant to magnetic drain plug fill plug and shipping plug for breather plug position and thread drain plug into its hole Fill with oil to fill level plug approximately 7 liters Install fill level plug and breather plug Page 17 Section 4 Axl eTech Assembly International TORQUE TABLE TYPE LOCATION TORQUE THREAD 1 N m COMPOUND MS 206012 1 hex head Pinion amp Output 11 15 Thread locker capscrew cage lock mean 13 0 Medium Carrier box housing strength M10 x 1 0 14X 1501 12 point head Diff case to case 12 97 Thread locker capscrew Bevel ring gear mean 84 5 High strength M12 x 1 25 10X 1543 hex head Carrier box housing 130 160 Thread locker capscrew mean 145 High s
23. d below the area where the output shaft will be pressed out of the ball bearing and the container have some soft impact material so the shaft is not damaged when pressed thru the ball bearing and personal injury does not occur Place these components on the workbench for later cleaning inspection and reassembly Removal Of The Carrier Assembly From The Carrier Box Assembly NOTE These capscrews have thread compound applied to the threads during production assembly 1 Loosen and remove the 12 M12X1 25 capscrews with washers from the carrier assembly to carrier box mounting pattern WARNING Take care when using lifting devices When you use a lifting strap inspect the strap for damage before you use it Do not use a lifting strap to shock load or drop load a component Serious personal injury and damage to components can result Page 5 Section 2 Disassembly 2 Attach the lifting strap and lifting device to the carrier input yoke in a safe method to apply tension to the strap See Figure 2 1 Figure 2 1 3 Use 2 M12x1 25 capscrews in the threaded holes at top and bottom or carrier to loosen and separate the carrier assembly from the carrier box 4 Remove the carrier assembly from the carrier box assembly and place safely and secure in either a carrier stand or on the workbench so the carrier will not fall and cause personal injury or component damage Carrier Disassembly Procedure Should the carrier upo
24. during production assembly 1 Remove the carrier input yoke 2 Remove the oil seal from the input cage assembly and discard 3 Remove the 2 capscrews M6X1 0 and lock plate from the carrier input bearing cage that retain input bearing cage in carrier assembly 4 Remove the bearing cage O ring and taper bearing cup by un screwing in a counter clockwise direction 5 Remove the spiral bevel pinion with 2 bearing cones and shims as an assembly The pinion bearings should be removed by using a hydraulic press with a similar procedure as item 7 Page 5 in removing the ball bearing from the output shafts above A suitable bearing puller must also be used behind the cone to remove the bearing cones The puller must fit correctly under the inner face of the cone to avoid damage to the cone Measure record and save for later re assembly any shims removed from behind inner bearing cone assembly on the spiral bevel pinion 6 Rotate the carrier assembly over for the ring gear facing upwards 7 Remove the cotter pin that lock the ring gear bearing adjusting ring and loosen the adjusting rings 8 Remove the differential bearing cap bolts and cap from the carrier assembly Section 2 Disassembly 9 Remove the adjusting ring and bearing cup from the bearing cap side Figure 2 5 Figure 2 5 COTTER CAP BOLT BEARING CAP ADJUSTING 10 Tilt the differential case and ring gear assembly slightly toward the
25. e 277 can be decreased by heating Refer to the following procedure A CAUTION Do not exceed 177 C 350 F maximum Heating must be done slowly to prevent thermal stresses in the other components 1 Heat the fastener for three to five seconds only Try to loosen the fastener with a wrench Do not use an impact wrench to loosen the fastener or hit the fastener with a hammer 2 Repeat Step 1 until you remove the fastener Page 11 Section 3 Prepare Parts for Assembly Installing Fasteners With Pre Applied Adhesive AxleTech Liquid Adhesive Loctite Liquid Adhesive or Equivalent Installing New Fasteners With Pre Applied Adhesive Patches 4 Clean the oil and dirt from threaded holes Use a wire brush CAUTION Do not apply adhesives or sealant on new fas teners with pre applied adhesive patches or inside closed threaded holes If other adhesives or sealants are used the new adhesive will not function correctly 2 Assemble the parts using the new pre applied adhesives fasteners NOTE There is no drying time required for fasteners with pre applied adhesive 3 Refer to Torque Table in Section 4 and tighten the fasteners to the specified torque Installing Original or Used Fasteners Using Thread Compounds During Assembly Three Bond 1305 and 1334 Loctite 241 242 243 271 and 273 or Equivalent WARNING Take care when you use adhesives thread locking compounds or any sealants to avoid
26. earing cap and bearing cap bolts Apply thread compound and tighten Refer to the Torque Table in Section 4 Figure 4 6 op Figure 4 5 Figure 4 6 COTTER CAP BOLT BEARING CAP ADJUSTING 4 Set differential case bearing preload and Bevel gearset backlash by turning adjusting rings 5 Use a small Ib in torque wrench at input yoke or else attach a spring scale to the yoke or clamping device Rotate the drive pinion by pulling the spring scale Observe the scale movement 6 Compare the preload measurement to Table A For example for the 2 917 carrier ratio if the pinion bearing preload measured 10 Ib in 1 13 Nem before installing the differential case assembly then the total bearing preload after installation should be between 13 4 18 6 lb in 1 5 2 1 Nem 7 Check the bevel gearset backlash Refer to Section 5 Page 16 AxleTech International 8 If the total bearing preload or bevel gearset backlash does not meet specification rotate the adjusting rings to get the target values 9 Check ring gear backface runout and gearset tooth contact pattern Refer to Section 5 10 Install the cotter pins to lock the adjusting rings Figure 4 6 Carrier Bearing Preloads lb inch Table A Carrier Total Differential Case Bearing Preload inch units Setting the Bearing Preload As Rolling Torque At Pinion e Assemble pinion assembly e Measure pinion bearing preload locate value unde
27. idance References to OSHA NIOSH MSHA and EPA which are regulatory agencies in the United States are made to provide further guidance to employers and workers employed within the United States Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance AxleTech International Table of Contents Exploded Views Center Assembly Carrier BOXE rccosecezcnscdeptatnedaeiesenswiesedaesdiiautaiieedecgaiindacteanasiaeoderdsntdainnsandeh ieadanudenbapdetlddaabariaes 2 CAMION ae ee een da ne oc oi oo 3 Section 1 Introduction SOIN de a ee D de ed ee ie 4 SCO ETE A EE S A AAA A A A 4 Section 2 Disassembly Camer ASS OR Se ee aol 4 Disassembly From VOICE A ed nee aa cames Ge eee nisana tnt iaaiaee niiina 5 Carrier Box Assembly Disassembly ne dan eo den studs eee ane eos ee 5 Removal of The Carrier Assembly From The Carrier Box Assembly 5 Carrier Disassembly POUR en ae da ee a D ee cu 6 Disassembly of the Differential Cases cccccceccccsseeccsseecceeeeeceueeeceuseecsueeecsageesseuseessaseessageeesacseeessaseensagses 8 Carer Box Final DIS ASS Sn a a KE 8 Section 3 Prepare Parts for Assembly Clean Ground or Polished Parts made scan ne sdete en na none snee encore en 9 Clean Parts With A Rough FInish cccccscccccsececceeceeceeeeecsseeecseeeseeeeceuseessaeeecageeesegeeessseesssseeesueeeseasenses 9 Clean The Camer Box IOUS IA a ee a a ee dd en ec at 9 Diving
28. inted in the USA AxleTech do Brasil Sistemas Automotivos Ltda Avendia Joao Batista 830 Centro Osasco SP 06097095 Brasil Phone 55 11 36846641 Fax 55 11 36846859
29. l prevent breakdown of assembly later Cleaning the Breather 1 Remove the breather from the carrier box assembly 2 Clean the breather If the breather remains dirty after you clean it replace the breather 3 Apply compressed air to the breather If the compressed air does not pass through the breather after cleaning replace the breather 4 Install the breather in the carrier box housing Page 9 Section 3 AxleTech Prepare Parts for Assembly International Tapered Roller Bearings e The centers of the large diameter end of the rollers are worn to a sharp edge Figure 3 3 Inspect the cup cone rollers and cage of all tapered roller bearings in the assembly If any of e Damage on rollers and on surfaces of the cup and the following conditions exist replace the bearing cone inner race that touch the rollers Figure 3 4 e The centers of the large diameter end of the rollers are worn level with or below the surface Figure 3 3 e The centers of the large diameter end of the rollers are worn to a sharp edge Figure 3 1 Figure 3 1 WORN RADIUS WEAR MARKS e A visible roller groove is worn in the cup or cone inner race surfaces You can see the groove at the small or large diameter ends of both parts Figure 3 4 WORN SURFACE e A visible roller groove in the cup or cone inner Figure 3 4 race surfaces The groove can be seen at the ETCHING AND small or large diameter end of both parts O Figure 3 2
30. n inspection require disassembly please follow the following steps after the carrier is securely retained for safe disassembly SO no personal injury can occur A carrier stand that will permit the carrier assembly is recommended as the carrier assembly must be rotated to teardown and built from both top and bottom access areas of the assembly WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service 1 Use a small lb in torque wrench at input yoke or else attach a spring scale to the yoke and rotate the yoke by pulling on the spring scale Observe and record the total preload measurement value indicated on the spring scale Figure 2 2 2 Measure and record the ring gear backface runout Figure 2 3 and the gearset backlash Figure 2 4 values 3 Using a snap ring pliers remove the snap ring from the carrier input yoke if used Page 6 AxleTech International Figure 2 2 Figure 2 3 Rotate ring gear NOTE exploded view shows item 13 as a lock nut which is available on later carrier designs Early production design uses a snap ring and washer to retain the input pinion yoke AxleTech International The input pinion lock nut can be removed using the same 2 options as the output shaft lock nut in item 4 Page 5 of the carrier box disassembly instruc tions above When a lock nut is fitted thread com pound has been used on pinion nut threads
31. ove dust from work clothes 6 Waste Disposal Dispose of discarded linings used rags cloths and HEPA filters with care such as in sealed plastic bags Consult applicable EPA state and local regulations on waste disposal Regulatory Guidance References to OSHA NIOSH MSHA and EPA which are regulatory agencies in the United States are made to provide further guidance to employers and workers employed within the United States Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance NON ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to non asbestos fiber dust a potential cancer and lung disease hazard Material Safety Data Sheets are available from Meritor Hazard Summary Most recently manufactured brake linings do not contain asbestos fibers These brake linings may contain one or more of a variety of ingredients including glass fibers mineral wool aramid fibers ceramic fibers and silica that can present health risks if inhaled Scientists disagree on the extent of the risks from exposure to these substances Nonetheless exposure to silica dust can cause silicosis a non cancerous lung disease Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing difficulty Some scientists believe other types of non asbestos fibers when inhaled can cause similar di
32. que yoke locknut per Torque Table in section 4 T The remaining steps are for versions with U joint yoke that uses snap ring washer and shims Figure 4 4 Section 4 Assembly 12 Slide U joint yoke onto pinion spline Install washer and snap ring with the beveled edge facing out Do not install shims yet 13 Measure axial endplay of U joint yoke which should fall within the 0 05 0 56 mm 0 002 0 022 inch range 14 Calculate shim pack thickness by adding 0 15 mm 0 006 inch to endplay and rounding down to the nearest 0 10 mm 0 004 inch Combine basic shims Refer to the table below Shim Pack Thickness mm 0 2 0 3 0 4 0 5 0 6 Number of ozmi 2 1 sasesme osme ili Example of shim selection measured axial endplay 0 42 ideal shim pack thickness 0 42 0 15 0 57 rounding down 0 5 from table 1 x 0 2 thick shim 1 x 0 3 thick shim 15 Disassemble snap ring and washer 16 Install shim pack washer and snap ring with the beveled edge facing out Washer contacts snap ring and not U joint yoke 17 Lightly tap yoke against carrier housing to help seat the snap ring Figure 4 4 OUTER PINION BEARING Installing the Differential Case Assembly 1 Apply the specified lubricant to the differential case bearings and cups 2 Install the differential case in the carrier Figure 4 5 Page 15 Section 4 Assembly 3 Install the bearing cups adjusting rings b
33. r Pinion Bearing e Assemble differential case and ring gear assembly e Measure total bearing preload it must be within range under Total Bearing Specified Rolling Torques lb in Pinion bearing preload 5 0 20 Differential bearing preload 10 0 25 0 Note 1 Ib in 0 113 N m 1 114 kgf cm Carrier Ratios 14x41 Teeth 12x35 Teeth 2 929 2 917 Pinion Total Bearing Bearing Min Max AxleTech International Installing Carrier Assembly Into Carrier Box 1 Apply Liquid Gasket Material to carrier assembly housing on the pilot diameter Figure 4 7 3 MM 0 125 MAXIMUM DIAMETER SILICONE GASKET MATERIAL BEAD 2 Insert carrier assembly into Carrier Box Item 1 aligning the screw holes 3 Install carrier nousing bolts and washers apply thread lock compound and tighten per Torque Table in Section 4 4 Lubricate output shafts O D and Ball Bearings and press on inner races ball bearings onto output shafts 5 Lubricate carrier box s output bores and assemble output shafts into carrier box until they engage differential side gears and press on outer races ball bearings into carrier box bores 6 Install oil seals into bearing cages flush with face of cages Air side should be visible after installation 7 Lubricate threads O ring grooves and ends of bearing cages Lubricate O rings install O rings in grooves and turn output bearing cages clockwise into carrier
34. r dust a cancer and lung disease hazard Material Safety Data Sheets are available from Axle Tech Hazard Summary Because some brake linings contain asbestos workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks Exposure to airborne asbestos dust can cause serious and possibly fatal diseases including asbestosis a chronic lung disease and cancer principally lung cancer and mesothelioma a cancer of the lining of the chest or abdominal cavities Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non smokers Symptoms of these diseases may not become apparent for 15 20 or more years after the first exposure to asbestos Accordingly workers must use caution to avoid creating and breathing dust when servicing brakes Specific recommended work practices for reducing exposure to asbestos dust follow Consult your employer for more details Recommended Work Practices 1 Separate Work Areas Whenever feasible service brakes in a separate area away from other operations to reduce risks to unprotected persons OSHA has set a maximum allowable level of exposure for asbestos of 0 1 f cc as an 8 hour time weighted average and 1 0 f cc averaged over a 30 minute period Scientists disagree however to what extent adherence to the maximum allowable exposure levels will eliminate the risk of disease that can
35. rienced mechanics knowledgeable in the installation repair and replacement of AxleTech Carrier Box Assembly Installation maintenance and replacement of AxleTech Carrier Box Assembly require a high degree of skill and experience The consequences of improper installation maintenance or replacement are grave and can result in vehicle drive failure and possible injury to or death of persons AxleTech does not authorize anyone other than highly skilled and experienced individuals to attempt to utilize the instructions contained in this Manual for the installation maintenance or replacement of AxleTech Carrier Box Assembly and AxleTech shall have no liability of any kind for damages arising out of or in connection with any other use of the information contained in this Manual Additional Publications For AxleTech service manuals please contact 1 877 877 9717 or visit our website at www axletech com How To Order Order items from AxleTech International Phone orders are also accepted by calling AxleTech International s Customer Service Center at 877 547 3907 or send a fax to 866 547 3987 For ArvinMeritor brake manuals please contact their Customer Service Center at 1 800 535 5560 or visit their website at www arvinmeritor com AxleTech International Asbestos and Non Asbestos Fibers ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to asbestos fibe
36. s and procedures when replacing seals to prevent incorrect installation and leaking seals Seals keep lubrication in and dirt out of a component When they are worn or damaged seals leak and produce damaging low lubricant levels that will damage components Oil Level Check and Adjust NOTE Separate fill and drain plugs are located on the carrier box assembly Correct procedure to check oil level in the carrier box assembly 1 Park the vehicle on a level surface Place blocks in front and back of the rear axle wheels to keep the vehicle from moving 2 Clean the area around the fill plug Remove the plug from the carrier box housing assembly The oil level must be level with the bottom of the fill plug hole e If the oil flows from the hole when you loosen the plug the oil level is high Drain the oil to the correct level NOTE Follow the vehicle manufacturer s recommendation of disposal of the oil drained from the carrier box assembly to assure disposal is in an environmentally friendly procedure Section 6 Lubrication NOTE Oil level too high may cause damage to the seals and other components It is essential the correct oil level be maintained for component damage not to occur e Ifthe oil level is below the bottom of the fill plug Add the specified oil according to the following procedure Fill the carrier box assembly with the specified oil through the fill plug hole Wait a few minutes to allow the oil
37. s toward the toe of the tooth and centered between the top and bottom of the tooth Figure 5 7 In used gearsets a good contact pattern fills approxi mately the full length of the tooth The top of the pat tern is near the top of the tooth The location should match the wear pattern on the tooth Figure 5 10 If the contact patterns require adjustment along the width of tooth top bottom follow Steps 4 5 If the contact patterns require adjustment along the length of tooth toe heel follow Steps 6 7 Figure 5 10 GOOD PATTERN IN OPERATION USED GEARS Page 21 Section 5 Adjustments 4 High Pattern high contact pattern indicates that the pinion was installed too shallow into the carri er Figure 5 8 To correct move the pinion toward the ring gear by decreasing the shim pack between pinion spigot and inner bearing cone Refer to Assembling the Pinion Bearing Cage in Section 4 Figure 5 11 Figure 5 11 Move pattern toward bottom A Decrease shim pack 5 Low Pattern A low contact pattern indicates that the pinion was installed too deep into the carrier Figure 5 9 To correct move the pinion away from the ring gear by increasing the shim pack between pinion spigot and inner bearing cone Refer to Assembling the Pinion Bearing Cage in Section 4 Figure 5 12 Figure 5 12 Move pattern toward top A Increase shim pack Page 22 AxleTech International 6 Heel Pattern Decrease
38. seases of the lung In addition silica dust and ceramic fiber dust are known to the State of California to cause lung cancer U S and international agencies have also determined that dust from mineral wool ceramic fibers and silica are potential causes of cancer Accordingly workers must use caution to avoid creating and breathing dust when servicing brakes Specific recommended work practices for reducing exposure to non asbestos dust follow Consult your employer for more details Recommended Work Practices 1 Separate Work Areas Whenever feasible service brakes in a separate area away from other operations to reduce risks to unprotected persons 2 Respiratory Protection OSHA has set a maximum allowable level of exposure for silica of 0 1 mg m as an 8 hour time weighted average Some manufacturers of non asbestos brake linings recommend that exposures to other ingredients found in non asbestos brake linings be kept below 1 0 f cc as an 8 hour time weighted average Scientists disagree however to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling non asbestos dust Therefore wear respiratory protection at all times during brake servicing beginning with the removal of the wheels Wear a respirator equipped with a high efficiency HEPA filter approved by NIOSH or MSHA if the exposures levels may exceed OSHA or manufacturer s recommended maximum levels
39. ssueesadeneseacdences 17 TOUS VA CR RS UNE 18 Section 5 Adjustments Checking the Ring Gear Backface Runout ins 19 Adjusting the Gearset Backlash sise 19 Adjusting Tooth Contact Pattern of the Gearset sn 20 Section 6 Lubrication Magnet Drain TP WEG RE E E AEA 23 SEEE U E AAE EE E ENEE E E EEE OEA E E A E EA EON I A AAE E E E EE 23 SOA ee e E E R Sd cad E odo anand a D ec 23 OPES EE EA E E E A V A T A A A AAN T E ET ET 23 Carrier Oil Box Recommendations ess me de ete nee eme me ie caen eine 0e 23 ADD VEC ONE SAS does onacabee es Sees ai alee EE 23 Approved Grease Recommendations for Carrier Box Assembly 23 Section 7 Tool Section How to Make a Yoke BE ccc cccccccacecccccececcencenuecuenueccenuectenceaenaeauesuusuenuesuestestestestectecusneeuesutcecceseseesnesneanes 24 Exploded View Center Assembly Carrier Box tem Description BRIE NE o eoma Page 2 Quantity 1 12 12 AxleTech International AxleTech International Exploded View Carrier Assembly oe 2 7 Rngsgad En o Pen Spa Bee e ouwsean ofore ooo asessson o Washer Side Gear mat 2 side GesrD WasherPion Twwst 4 Prion E ser EE ES Gear Spas EE Page 3 Ni ajaja Section 1 Description Carrier Box Service Manual Identification To determine the exact axle model and specification refer to the identification tag located on the carrier box assem
40. t End of pinion gear head or outer diameter of ring gear Page 13 Section 4 AxleTech Assembly International Assembling the Pinion 4 Install the following components in the ring gear Bearing Cage case half e Spider 4 pinion differential nests Figure 4 1 e Differential pinions and washers WARNING To prevent serious eye injury always wear safe LE nr eye protection when you perform vehicle SIDE GEAR AND maintenance or service PINION AND THRUST WASHER Observe all warnings and cautions provided by DIFFERENTIAL CACHE the press manufacturer to avoid damage to CASE HALF components and serious personal injury 1 Place the bearing cage in a press 2 Support the bearing cage with metal or wood blocks 3 Press the bearing cup into bore of the carrier Inspect inside 5 housing or bearing cage until the cup is flat Bungee JA x against bottom of bore Use the correct size 4 IN co sleeve to install cup Inspect C7 4 Press the outer bearing cone onto the shaft of the drive pinion until the cone is flat against the gear head Use a correct size sleeve against the bearing inner race 5 Install the other differential case half on top of the case half you assembled in Step 4 matching spider legs to half round slots 6 Install the ring gear on the case half Align the reference marks made during disassembly If necessary heat the ring gear to 140 C 284 F 6 Press the inner bearing cone onto the drive pinion
41. ten procedures for servicing brakes provided that the exposure levels associated with the employer s procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment Consult OSHA regulations for more details d Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos when grinding or machining brake linings In addition do such work in an area with a local exhaust ventilation system equipped with a HEPA filter e NEVER use compressed air by itself dry brushing or a vacuum not equipped with a HEPA filter when cleaning brake parts or assemblies NEVER use carcinogenic solvents flammable solvents or solvents that can damage brake components as wetting agents 4 Cleaning Work Areas Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping NEVER use compressed air or dry sweeping to clean work areas When you empty vacuum cleaners and handle used rags wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos When you replace a HEPA filter wet the filter with a fine mist of water and dispose of the used filter with care 5 Worker Clean Up After servicing brakes wash your hands before you eat drink or smoke Shower after work Do not wear work clothes home Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn Launder them separately Do not shake or use compressed air to rem
42. the gearset backlash with in specified range to move contact pattern toward toe and away from heel Refer to Adjusting the Gearset Backlash in this section Figure 5 13 Figure 5 13 Move pattern toward toe Loosen adjusting ring this side amp Decrease backlash TT SSS a N p i RAMOS SON SNS Tighten adjusting ring this side 7 Toe Pattern Increase the gearset backlash within specified range to move contact pattern toward heel and away from toe Refer to Adjusting the Gearset Backlash in this section Figure 5 14 Figure 5 14 Move pattern toward heel Tighten adjusting ring this side TT en IR S n NASN ASSN Increase backlash Loosen adjusting ring this side AxleTech International Magnet Drain Plug Specific oils other than those listed should have approval prior NOTE Inspect the magnetic drain plug each time the oil is changed Use the correct part Pipe plugs will leak if used as a drain plug The magnetic drain plug can be reused if after cleaning the plug has a minimum pick up capacity of 20 ounces 0 57 kg of low carbon steel Breather CAUTION Cover the breather when steam cleaning the carrier box housing to prevent water from entering the carrier box and contaminating the oil Damage to components will result Breathers release pressure and vacuum condensation to help maximize oil and component life Seals CAUTION Always use the correct tool
43. trength M14 x 2 MS 214065 1 hex head Diff case brg cap 190 230 Thread locker capscrew Carrier box housing mean 210 Medium strength M24 x 1 5 40X 1099 Flanged Yoke nut Pinion amp 400 540 Thread locker 088178 3 locknut Output shaft mean 470 Medium strength Apply to Nut 3 8 18 NPSF A 1199 P 1394 Vent Plug Plug vent Breather 28 Minimum Sealant RTV Carrier box assembly or Permatex 51 3 8 18 NPSF P 26 Shipping Plug Breather Location 28 Minimum Sealant RTV Carrier box assembly or Permatex 51 3 4 14 NPSF P 212 Plug Plug lube fill or level 48 68 Sealant RTV Carrier box assembly mean 58 or Permatex 51 3 4 14 NPSF 1850 T 150 Magnetic Plug lube drain 48 68 Sealant RTV Plug Carrier box assembly mean 58 or Permatex 51 Notes 1 Oil is AGCO Permantran 821 XL transmission and hydraulic oil or equivalent Approved thread locking compounds Medium strength Loctite 241 242 243 ThreeBond 1334 High strength Loctite 271 273 ThreeBond 1305 Sealants Loctite Ultra Grey RTV Permatex 51 Page 18 AxleTech International Checking the Ring Gear Backface Runout Runout Specification 0 20 mm 0 008 inch maximum Attach a dial indicator on the mounting flange of the carrier 2 Adjust the dial indicator so that the plunger or pointer is against the back surface of the ring gear 3 Set the dial indicator to zero 0 4 Rotate the ring gear and re
44. y has been done with above recommended grease used and recommendation is to continue with similar grease in service Page 23 Section 7 Tool Section How to Make a Yoke Bar 1 Measure dimensions A and B of the yoke you are servicing Figure 7 1 2 Calculate dimensions C and D of the yoke bar by adding 0 125 0 250 inch to dimensions A and B of the yoke Figure 7 2 WARNING Wear safe clothing and eye protection when you use welding equipment Welding equipment can burn you and cause serious personal injury Follow the operating instructions and safety pro cedures recommended by the welding equipment manufacturer 3 To make the box section cut and weld 1 0 inch x 2 0 inch mild steel square stock according to dimensions C and D Figure 7 2 4 Cut a 4 0 foot x 1 25 inch piece of mild steel round stock to make the yoke bar handle Center weld this piece to the box section Figure 7 2 e To increase yoke bar rigidity Weld two angle pieces onto the handle Figure 7 2 Page 24 AxleTech International AxleTech International Suite 400 3001 West Big Beaver Road Troy Michigan 48084 U S A Toll Free 877 877 9717 Non Toll Free 248 816 5401 Fax 248 435 1990 Website www axletech com MMXX Issued 06 04 AxleTech International France 4 Rue Jean Servanton Boite Postale 656 42042 Saint Etienne C dex 1 France 33 477 92 88 00 Fax 33 477 92 88 93 Copyright AxleTech International Pr
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