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48T300 Service Manual 0183

1. Item Description Qty 1 Cotter Pin Input Flange Nut 1 2 Nut Input Flange 1 3 Washer Input Flange 1 4 Flange Input 1 5 Shield Input Flange Dust 1 6 Oil Seal Input Shaft 1 7 Capscrew Carrier Cover 11 8 Lockwasher Carrier Cover Capscrew 11 9 Cover Carrier 1 10 Spacer Input Flange To Bearing 1 11 Capscrew Input Shaft Bearing Retainer 8 12 Lockwasher Input Shaft Brg Retainer 8 13 Retainer Input Shaft Outer Bearing 1 14 Shim Input Shaft Bearing Retainer 004 AR 15 Shim Input Shaft Bearing Retainer 007 AR 16 Shim Input Shaft Bearing Retainer 010 AR 17 Cup Input Shaft Bearing 1 18 Cone Input Shaft Bearing 1 19 Screw Thrust 1 20 Nut Thrust Screw 1 21 Nut Differential Adjusting 2 22 Cup Differential Bearing 2 23 Cone Differential Bearing 2 24 Gear Input Drop 1 25 Cover Drop Gear Access 1 26 Lockwasher Drop Gear Access Cover 6 27 Capscrew Drop Gear Access Cover 6 28 Stud Carrier Cap 4 29 Washer Carrier Cap 4 30 Nut Carrier Cap Stud 4 31 Shaft Input and Drop Gear 1 32 Bearing Cone Input Shaft 1 33 Bearing Cup Input Shaft 1 34 Washer Snap Ring 1 35 Snap Ring Bearing Retaining 1 Item Description Qty 36 Capscrew Ring Gear 12 37 Nut Ring Gear Capscrew 12 38 Flanged Half Differe
2. Figure 250 Figure 253 Place ring gear differential half Proper alignment of ring gear mounting screw heads with inside diameter of ring gear counter bore 71 48T300 Drive Axle Service Manual Figure 254 Apply Loctite 262 or equivalent to ring gear mounting screws Figure 255 Install 12 ring gear mounting screw nuts and tighten to 175 190 LBF FT 240 260 Nm Differential Body and Ring Gear Installation F us Figure 256 Set differential assembly into carrier 1 Figure 257 Lubricate 2 differential bearing cones with axle lubricant Figure 258 Install 2 differential bearing cups Figure 259 Install 2 differential adjusting nuts 48T300 Drive Axle Service Manual Figure 260 Tighten both adjusting nuts to take up all clearance in the differential bearings Rock ring gear back and forth during this process to check for backlash Carrier Cap Installation H n Figure 261 Install both carrier caps Line up identification marks made during disassembly Figure 262 Install 4 carrier nuts and washers Tighten only enough to seat caps at this time Setting Ring Gear Backlash Figure 263 Using a dial indicator as shown check ring gear and pinion backlash Backlas
3. Figure 158 Figure 161 Clean cured thread locking compound from holes Install 2 wear indicator pin o rings and lubricate with a 625 11 UNRC 2A tap Use compressed air to remove residue from holes Use appropriate eye protection when using compressed air Fre i E i Figure 159 Figure 162 Position brake housing blocks as shown to Install wear indicator pin in housing allow clearance for the wear indicator pin Pin will protrude through bottom of housing Pressure Ring and Spring Installation Wear Indicator Pin Installation N Figure 163 Figure 160 Lubricate pressure ring o ring sealing surface with grease Install wear indicator pin retaining ring 55 48T300 Drive Axle Service Manual Figure 164 Figure 167 Install brake spring sets Set pressure ring into position A lifting device similar to the one shown can ease installation Refer to tool drawing on page 98 Brake Disc Installation Figure 165 Lubricate brake cover seal ring with grease and install wi Figure 168 Install reaction disc Figure 166 Figure 169 Lubricate seal ring with grease and install on pressure ring Identify the rounded edges on teeth of friction discs Rounded edges should be installed facing UP 56 48T300 Drive Axle Service
4. Figure 14 1 Install 2 screws with flat washers at 4 00 amp 8 00 m to positions as shown to retain internal gear Figure 17 Remove face seal from hub Figure 15 Figure 18 Remove hub assembly Remove face seal from brake housing 29 48T300 Drive Axle Service Manual Brake and Spindle Removal Figure 22 Loosen top mounting screw 18 to 1 torque multiplier is shown Figure 19 Remove 1 brake cover attaching screw at 12 00 position Figure 20 Figure 23 Install lifting device Remove spindle mounting screw as shown Refer to tool drawing on page 99 Figure 21 Figure 24 Attach chain Approximate balance point is shown Install alignment pin 30 48T300 Drive Axle Service Manual Figure 25 u Figure 28 Threaded end of pin must engage threads in axle housing Carefully remove brake assembly a minimum of 1 5 times pin diameter or 2 0 50 8 mm IE er 4 Figure 29 Figure 26 Remove brake to spindle seal ring Remove remaining 12 brake and spindle mounting screws Figure 30 Remove spindle Spindle is heavy and weighted off center Remove spindle retaining ring Do not clean chase axle housing threads using a tap
5. Figure 84 Remove input flange nut and washer Figure 85 Remove input flange Figure 86 Remove input flange dust shield NOTE Remove only if replacement is required Figure 87 Loosen thrust screw lock nut Figure 88 Remove thrust screw 42 48T300 Drive Axle Service Manual Differential and Ring Gear Removal Figure 8 Mark carrier and caps to identify for reassembly Figure 90 Remove 2 differential adjusting nut lock screws and lock washers w Ane Figure 91 Remove 4 carrier cap nuts and washers Figure 92 Remove carrier caps Figure 93 Remove differential adjusting nuts Figure 94 Remove bearing cups 43 48T300 Drive Axle Service Manual Figure 95 mm Figure 98 Remove differential assembly Remove cover Input amp Drop Gear Shaft Removal Figure 96 Figure 99 Remove 11 carrier cover screws and lock washers Remove input shaft oil seal from carrier cover Figure 97 Figure 100 Carefully pry carrier cover from housing Remove 8 input shaft outer bearing retainer screws and lock washers 44 48T300 Drive Axle Service Manual Figure 101 Carefully pry outer bearing retainer from
6. EI Figure 337 Apply Loctite 262 or equivalent to 6 spindle nut lock plate screws and install 86 481300 Drive Axle Service Manual H Figure 338 Figure 341 Tighten spindle nut lock plate screws to Install 4 differential mounting tapered dowels 25 28 LBF FT 34 38 Nm Differential and Carrier Installation p c Figure 342 Figure 339 Install 14 differential mounting stud washers Apply 09 2 3 mm continuous bead of RTV sealant to Differential and carrier mounting surface of axle housing 1 ih Figure 340 Figure 343 Install differential and carrier assembly Apply Loctite 262 or equivalent to differential mounting stud threads 87 48T300 Drive Axle Service Manual h y A A 15 ET 11 F A Figure 344 Install 3 twelve point differential mounting stud nuts in locations shown Install 11 six point nuts on remaining studs Figure 345 Tighten 14 differential mounting nuts to 175 190 LBF FT 237 258 Nm Figure 346 Remove lifting chain screws and flat washers 88 Figure 347 Apply Loctite 262 or equivalent to 2 carrier cover screws and install with lock washers Figure 348 Tighten 2 carrier cover screws to 65 70 LBF FT
7. Figure 356 Install axle shaft Figure 357 Figure 360 Install sun gear on axle shaft Install planetary assembly a m Planetary Installation x E 1 i m A Figure 358 361 Apply grease to planet sealing Apply Loctite 262 or equivalent to 3 mounting screws ring surface in wheel hub 90 48T300 Drive Axle Service Manual E Figure 362 Install 3 planetary mounting screws IMPORTANT Align casting eye brows with each other as shown The 3 screw locations are identified by small cast buttons on the face of the planet carrier A an 28 Figure 363 Tighten planetary mounting screws to 380 400 LBF FT 515 542 Nm Figure 364 Install planetary oil level and drain plugs and tighten to 30 35 LBF FT 41 47 Nm Output Flange Installation M JB P N EC pi SN 7 1 D ss a 33 xj Figure 365 Pack output shaft oil seal with grease and apply heavy coat to outer NOTE Input and drop gear shaft not as shown Figure 366 If replacement is required install output flange dust shield using appropriate driver r Figure 367 Install output flan
8. 31 48T300 Drive Axle Service Manual Figure 31 Figure 34 Remove spindle pilot seal ring Remove output flange dust shield NOTE Remove only if replacement is required Figure 32 Figure 35 Remove spindle to axle housing seal ring Pry bearing and oil seal retainer away from axle housing and remove Using appropriate puller remove outer Output Flange and Bearing Removal roller bearing bearing spacer and inner roller bearing Figure 33 Figure 36 Remove cotter pin flange nut washer output flange Remove bearing and oil seal retainer o ring and 7 bearing amp oil seal retainer nuts and lockwashers 32 48T300 Drive Axle Service Manual na 4 1 1 Figure 37 Figure 40 Remove oil seal as shown or drive Remove 4 tapered dowels out from back side with a punch Differential and Carrier Assembly Removal Figure 41 i i Remove 2 carrier cover screws on horizontal center line of pinion shaft gt _ gt m Figure 42 Install lifting chain with 2 screws and flat washers NOTE Length of screws must be the length of the screws removed plus the thickness of the chain used to assure adequate engagement of threads Figure 39 Remove 11 differential
9. Figure 70 Tap out brake wear indicator pin T _ Figure 71 Remove brake wear indicator pin lt gt Piston Removal Figure 72 Place brake cover on flat surface face down Install 3 screws and flat washers in the brake piston puller holes Brake cover is heavy and can cause injury and damage Figure 73 Piston with puller screws and washers installed Figure 74 Using a pry bar evenly pry piston out of the brake cover until it is no longer in contact with the piston seals 48T300 Drive Axle Service Manual Figure 75 B Figure 78 Piston pulled out of seals Remove inner piston seal assembly Piston can be removed by hand at this point Figure 76 Figure 79 Remove brake piston Remove 2 pressure port sealing rings Figure 77 Figure 80 Remove outer piston seal assembly Remove pressure ring seal ring 40 48T300 Drive Axle Service Manual Figure 81 Remove 2 brake wear indicator pin o rings Figure 82 Remove brake wear indicator pin retaining ring NOTE Not necessary to remove unless replacement is required Clean and inspect all components Repair or replace components as required 41 48T300 Drive Axle Service Manual Differential and Carrier Disassembly Input Flange Removal Figure 83 Remove input flange nut cotter pin
10. 88 95 Nm Figure 349 Apply teflon thread sealer to differential drain plug and install Tighten to 40 45 LBF FT 54 61 Nm 48T300 Drive Axle Service Manual Figure 350 Apply teflon thread sealer to axle drain plug and install Tighten to 50 55 LBF FT 68 74 Nm Output Bearing amp Retainer Installation Figure 351 Using appropriate driver install inner roller bearing bearing spacer and outer roller bearing NOTE Be sure bearings are properly seated against shaft shoulder Figure 352 Using appropriate driver install oil seal in bearing and oil seal retainer Install bearing and seal retainer o ring NOTES Dust lip on seal must be positioned with lip facing out Sealant should not be used 89 Ee Figure 353 Insert bearing and seal retainer into axle housing while guiding the outer roller bearing into the retainer bore NOTE Shown without oil seal Figure 354 Install 7 lock washers and apply Loctite 262 or equivalent to stud threads NOTE Input and drop gear shaft not as shown 31 258 Figure 355 Install 7 nuts and tighten to 40 45 LBF FT 54 61 Nm NOTE Input and drop gear shaft not as shown 48T300 Drive Axle Service Manual Axle Shaft and Sun Gear Installation Figure 359 Apply grease and install planetary o ring
11. IMPORTANT Do not remove more than one screw at a time Figure 187 Install 2 warning sticker covers with 4 screws and tighten to 215 240 LBF IN 24 27 Nm 59 48T300 Drive Axle Service Manual Differential and Carrier Reassembly Figure 188 Using appropriate driver install pinion shaft outer bearing cup Figure 191 Using appropriate driver install pinion shaft inner cup z F Figure 189 Using appropriate driver install input shaft inner bearing cup Calculating and Installing Pinion Shims uh Figure 192 Using a 002 feeler gage check to be sure inner and outer bearing cups are seated in bores When cups are properly seated the feeler gage should not fit between the cups or shims and carrier housing shoulder Check several locations around the cup diameter Refer to bearing heating and freezing guidelines on page 14 Figure 190 Install the original or same thickness inner pinion bearing cup shim pack if reinstalling the original ring and pinion set If installing a new ring and pinion set compare the etched numbers on the ring gears and adjust the shim pack accordingly The total length of the etched number and shim thickness of new ring and pinion should be the same as the old ring and pinion number and shim pack Refer to Figure 193 detailed depth sett
12. 14 15 17 18 19 20 21 22 23 24 25 26 27 27 28 29 30 32 33 34 34 37 37 38 39 39 42 42 43 44 46 48 49 TABLE OF CONTENTS Foreword And Safety Precautions Table of Contents Description Axle Assembly Exploded View Axle Assembly Parts Description Diff and Carrier Assembly Exploded View Diff and Carrier Assembly Parts Description Brake Assembly Exploded View Brake Assembly Parts Description Planet Assembly Parts Description Oil Checking Procedure Recommended Lubricants Bearing Heating and Freezing Guidelines Cleaning and Inspection Axle Reassembly Pinion Depth Setting Procedure Wheel Bearing Adjusting Instructions Face Seal Installation Instructions Posi Stop Brake Pressure Test Instructions Axle Pressure Test Instructions Tooth Bearing Chart LH Tooth Bearing Chart RH Fastener Torque Chart Plug and Elastic Stop Nut Torque Charts DISASSEMBLY SECTION Axle Disassembly Planetary Removal Axle Shaft and Hub Removal Face Seal Removal Brake and Spindle Removal Output Flange and Bearing Removal Differential and Carrier Assembly Removal Planetary Disassembly Hub Disassembly Posi Stop Brake Disassembly Brake Cover Removal Brake Discs Piston and Spring Removal Wear Indicator Pin Removal Piston Removal Differential and Carrier Disassembly Input Flange Removal Differential and Ring Gear Removal Input and Drop Gear Shaft Removal Pinion and Drop Gear Removal Ring Gear Removal
13. 18 1 2 14 3 4 14 1 11 1 2 1 1 4 11 1 2 Size ELASTIC STOP NUTS LBF FT 26 48T300 Drive Axle Service Manual Figure 1 Drain oil from wheel ends brakes and center section Figure 2 Remove 3 planet carrier screws Figure 3 Pry planet carrier out of wheel hub enough to install chain clevis Use care not to over extend planet carrier as serious injury can result 27 DISASSEMBLY Planetary Removal W m i E Figure 4 Install chain clevis Figure 5 Attach chain Figure 6 Remove planet carrier from hub 48T300 Drive Axle Service Manual Figure 7 Remove sun gear Figure 10 Remove 6 lock plate screws Figure 8 Remove planet carrier o ring Figure 11 Remove spindle nut lock plate Axle Shaft and Hub Removal Figure 9 Remove axle shaft 28 Figure 12 Remove spindle nut 48T300 Drive Axle Service Manual Face Seal Removal Figure 13 Install lifting device Refer to tool drawing on page 99 Figure 16 Carefully pry face seal from hub Avoid making contact with seal bore or sealing surfaces that could cause damage and leaks
14. ALL SAFETY PRECAUTIONS COMPLIED TO 1 Disassemble wheel end from spindle up to and including the removal of the wheel hub from the brake discs NOTE If axle spindle or axle housing is to be replaced remove brake as an assembly by removing brake to spindle screws and washers Remove brake assembly from spindle It is imperative that a special disassembly and reassembly spring compression tool be fabricated before disassembling any part of this brake a drawing of the tool is included on page 98 2 Install spring compression tool main section over axle spindle through brake discs and against the piston pressure ring 3 Install the bolt plate and bolts over the spindle Back the bolts out far enough so they do not contact the cylinder face 4 Install spindle nut and tighten securely against compression tool D Tighten the four 4 compression tool bolts against compression tool cylinder This will hold the springs in position while removing the brake cover and brake discs WARNING OUTER BRAKE HOUSING COVER IS UNDER 72 000 LBS COMPRESSED SPRING PRESSURE AND EXTREME CAUTION MUST BE TAKEN IN REMOVING THIS COVER BRAKE COVER BOLTS MUST BE REMOVED CAUTIOUSLY AND EVENLY DO NOT REMOVE BRAKE COVER BOLTS ONE 1 AT A TIME 6 With the spring compression tool securely in place remove the brake cover bolts evenly Do not remove bolts one at a time 7 Remove brake cover and piston from brake housing 8 Remove the friction and reactio
15. Axle Service Manual Figure 242 Figure 245 Install 3 inner clutch discs on side gear Place the differential body plain half on the flanged half IMPORTANT Line up the identification marks made during disassembly _ aL hm FH Figure 243 Figure 246 Install 4 outer clutch discs on side gear Apply Loctite 262 or equivalent to 12 aligning outer tangs of discs with each other differential body screws and install with washers 3 ES Figure 244 Figure 247 Proper clutch disc stack up and alignment Tighten differential body screws to 175 190 LBF FT 237 258 Nm 70 48T300 Drive Axle Service Manual lt gt Ring Gear Installation Figure 251 Align holes in ring gear with holes in differential body flange Insert 12 ring gear mounting screws Figure 248 Use a hone stone or file to remove nicks or burrs from ring gear mounting face NOTE Be sure to remove all abrasive residue TUS Figure 249 Use a hone stone or file to remove nicks or burrs from ring gear mounting face NOTE Be sure to remove all abrasive residue Figure 252 Tap 12 ring gear mounting screws into fully seated position IMPORTANT Correct alignment of screw heads shown in figure 253
16. Brake Piston Lifting Tool Wheel Hub and Brake Lifting Tool Pinion Locking Tool Pinion Pressing Tool Hub Seal Driver 481300 Drive Service Manual DESCRIPTION The axle assembly has a bevel type ring gear and pinion with further reduction provided by a planetary gear set within the wheel hub Primary Reduction The spiral bevel pinion and ring gear transmit power through the center differential pinions side gears and to the axle shaft The spiral bevel differential assembly is mounted on tapered roller bearings which are adjusted by the positioning of the two threaded adjusting nuts mounted in the differential carrier and cap assembly The pinion bearing preload is adjusted and maintained by a hardened and precision ground spacer positioned between inner and outer bearings The spacer is selected at assembly Secondary Reduction In the wheel hub a self centering sun gear is spline fitted to the axle shaft and drives three planetary pinion gears These gears in turn mesh with and react against a rigidly mounted internal ring gear The planet gears rotate on needle roller bearings mounted on hardened and ground pins located in the planet carrier which in turn drive the wheel hub Positive lubrication keeps all moving parts bathed in lubricant to reduce friction heat and wear Posi Stop LCB Liquid Cooled Brakes The liquid cooled brake is ideal for use in contaminated or temperature sensitive environments and in mach
17. Differential Disassembly 52 52 53 54 55 55 55 56 57 58 60 60 61 63 66 67 71 72 73 73 74 75 75 76 77 78 79 81 82 84 86 87 89 90 90 91 92 95 95 98 99 100 101 102 REASSEMBLY SECTION Axle Reassembly Planetary Reassembly Hub Reassembly Internal Ring Gear Assembly amp Installation Posi Stop Brake Reassembly Wear Indicator Pin Installation Pressure Ring and Spring Installation Brake Disc Installation Piston Installation Cover Installation Differential and Carrier Reassembly Calculating and Installing Pinion Shims Pinion Gear Installation and Preload Input and Drop Gear Shaft Installation Setting Input and Drop Gear Shaft End Play Differential Body Assembly Ring Gear Installation Diff Body and Ring Gear Installation Carrier Cap Installation Setting Ring Gear Backlash Drop Gear Cover Installation Input Flange Spacer Installation Carrier Cover Installation Input Flange Installation Checking Ring Gear Contact Pattern Thrust Screw Installation Spindle and Brake Installation Hub Installation Face Seal Installation Wheel Bearing Preload Adjustment Brake Cavity and Seal Air Test Differential and Carrier Installation Output Bearing amp Seal Retainer Installation Axle Shaft and Sun Gear Installation Planetary Installation Output Flange Installation Axle Air Pressure Test SPECIAL TOOL SECTION Brake Spring Compression Tool Instructions Brake Spring Compression Tool Drawing
18. gear and not more than 1500 engine rpm Wide turns both left and right should be made to work the differential then drain Be sure to drain all of the flushing oil before refilling with new oil by following the draining procedure above make sure all the flushing oil has been removed Inspect the magnetic drain plug for metal particles or other foreign matter indicative of wear or possible failure Then fill with the recommended lubricant Note When filling the axle housing planetary wheel ends and brakes allow enough time for lubricant to flow through the various components in the differential planetary housing and the brake assembly After filling is completed allow a few minutes for lubricant to attain its level and recheck each wheel end and the axle center Add lubricant if necessary 12 48T300 Drive Axle Service Manual ug RECOMMENDED LUBRICANTS Recommendations Extreme pressure gear lubricant is recommended for use in all drive steer and rigid drive axles except where explicitly stated differently by Spicer Off Highway Products Engineering Mineral Based Acceptable lubricants must meet API GL 5 MT or MIL PRF2105E qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below Synthetics Synthetic lubricants are recommended providing they meet API GL 5 MT 1 qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from
19. mounting nuts and washers 99 48T300 Drive Axle Service Manual Figure 43 Remove differential and carrier assembly Planetary Disassembly Figure 44 Remove 4 retaining rings Figure 45 OPTIONAL Apply heat to inner bearing race to facilitate removal Refer to bearing heating and freezing guidelines on page 14 34 Figure 46 Remove 4 gear and bearing assemblies Inspect bearing contact surfaces for wear and damage Figure 47 Remove thrust washer as shown Clean and inspect all components Repair or replace components as required Hub Disassembly Figure 48 Block hub to secure as shown Remove lifting device 48T300 Drive Axle Service Manual Figure 49 Remove 2 screws and flat washers Figure 50 Carefully remove internal ring gear and hub assembly from hub Ring gear assembly is heavy Refer to exploded view and parts description on pages 5 and 6 for this procedure Figure 51 Remove internal ring gear snap ring Item 28 Separate internal gear hub Item 27 from internal ring gear Item 26 35 Figure 52 OPTIONAL Apply heat to inner race of bearing cone to facilitate removal Refer to bearing heating and freezing guidelines on page 14 NOTES If using heat immedi ately proceed to step in figure 53 before bearing cools NOTE Inter
20. same thickness shim pack that was removed Figure 218 Figure 221 Using appropriate driver install Position bearing retainer on alignment pin input shaft outer bearing cup Figure 219 Install 1 alignment pin in bolt circle around Install 4 input bearing retainer screws and lock input shaft bearing NOTE Alignment pin can washers in every other hole and tighten to be made by removing the head from a bolt 65 40 LBF FT 88 95 Nm 65 48T300 Drive Axle Service Manual Setting Input and Drop Gear Shaft End Play Figure 223 STEP 1 Using a dial indicator and pry bar as shown pry between bottom of drop gear and housing to measure input shaft end play and record value If no end play exists add shims to obtain approximately 004 006 102 152 end play STEP 2 Using a dial type torque wrench measure the no load rolling torque of the input shaft assembly and record value STEP 3 Calculate shim pack thickness by subtracting the amount of recorded end play from step 1 less an additional 002 0 050mm from the total shim pack thickness EXAMPLE 0 080 2 032mm Initial Shim Pack Thickness 0 004 0 100mm End Clearance From Step 1 0 002 0 050mm Bearing Preload 0 074 1 882mm Desired Shim Pack Thickness STEP 4 Remove input bearing retainer screws bearing retainer and shims Install desired shim pack as determined in step 3 and reinstall bearing r
21. the chart below In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases This produces a thickening of the mineral oil at the contact point This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and spalling fatigue Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so Before using a synthetic lubricant in heavy applications the customer must check with the lubricant supplier on the issue of high pressure lubricant applications Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgment must be used to determine the required change intervals for extreme conditions Extended Oil Change Interval Extended oil service may result when using synthetic lubricants Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a baseline Wear metal analysis can provide useful information but an axle should not be removed from service based solely on this analysis Vehicles which are prone to high
22. 1 00x 2 81 E11 50 x 1 00x 20 00 HAS 100 PRESSING TOOL 48T300 Drive Axle Service Manual STAR PN m one Reco MATL iA Boo Powt 4 LAMP HALDE 8 100 5 TAP Duele 551 Dan DERILLTTHRL Holes E a m TE m amas ern 11 4 I 1 L e Lu m 41 101 MEDIUM KHURL STAMP TOOL NUMBER HUB SEAL DRIVER 3 31 8441 MIN RELIEF BLACK OXIDE 9 x PE gt TG oz Ie 1500 Gimn JO 38 1mm ex je 45 Lonn 3 00 76 27 15mm J 300 7 6 2mnJ 375 847 6 5mm 102 45 E 19mmJ DRIVER 1 REOG D MATL 57 DR EQUIV HDN Rc 45 50 _ BLACK LIXIDE
23. 9 034 IVIYILYN S310N 1123 29 2 97 090 YIINVHO 000 119 DoE ZIG SNId H3AO 434 000261 TTK Lo V 008 8917 00076 008 1 lt NMOHS SV 39714 H19N31 2972 X Nid 005 0 95 48T300 Drive Axle Service Manual SS3NQ4VH 32 484 5 87 07 OL 934131 3 0 1V3Ml LV3H 2 12288 H2298 HO298 3MVNW VIHN3IVW S310N V V NOITI23S Axle Models 53R amp 48T 3913 F 1 dVl Hl 2 1 082 BRAKE SPRING COMPRESSION TOOL BOLT PLATE 96 481300 DANA Service Manual d BRAKE SPRING COMPRESSION TOOL INSTALLATION aum 5 LX EOE c la 1 spindle Mut 1 250 7 UNG 2A x 500 HEX HEAD CAP SCREW 4 REQ D 97 48T300 Drive Axle Service Manual BRAKE PISTON LIFTING TOOL 98 WHEEL HUB AND LIFTING TOOL 48T300 Drive Axle Service Manual Q 68 THRU B 45 25 6 PLCS 15 X 2 00 X 5 50 15 X 2 00 X 0 00 DESCRIPTION LIFTING DEVICE WELDMENT REO D STRESS RELIEVE _ FLAME HARDEN AROUND HOLE 99 PINION LOCKING TOOL 9 x PE gt TG oz WELDED CONSTRUCTION 1 8600 NORMALIZE 209 4 25 415 A 2 LL e 011 1 00x
24. AY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RESULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION FIG 4 LOW BEARING ON GEAR AND HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIOLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 23 481300 Drive DANA Service Manual GEAR TOOTH CONTACT CHART RH PINION TOWARD MOVE PINION AWAY FROM GEAR IN THIS DIRECTION Wem MOVE GEAR AWAY FROM MOVE GEAR T PINION IN THIS DIRECTION PINION IN ALL CONTACT BEARINGS SHOWN BELOW ARE ON BIGHT HAND SPIRAL RING GEAR THE 15 ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER A LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION FIG 3 HEEL BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY AND COULD RESULT IN EARLY GEAR FAILURE TO MOVE BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD PINION FIG 4 LOW BEARING ON GEAR AN
25. D HIGH BEARING ON PINION CORRECT BY PULLING PINION AWAY FROM GEAR INCREASE MOUNTING DISTANCE FIG 5 HIGH BEARING ON GEAR AND LOW BEARING ON PINION CORRECT BY MOVING PINION TOWARD GEAR DECREASE MOUNTING DISTANCE BACKLASH BACKLASH SHOULD BE MEASURED WITH DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL SEE SHEET NO 2 FOR BACKLASH VALUES 24 48T300 Drive Axle Service Manual FASTENER TORQUE CHART STANDARD FASTENERS Lubricated and Plated Bolts CapScrews and Studs Grade 8 6 Radial Dashes On Bolt Head LBF FT Nm Grade 5 3 Radial Dashes On Bolt Head LBF FT Nm 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 METRIC FASTENERS Lubricated and Plated Bolts CapScrews and Studs Class 8 8 Class 10 9 Class 12 9 8 8 on Bolt Head 10 9 on Bolt Head 12 9 on Bolt Head LBF FT Nm LBF FT Nm LBF FT Nm 25 48T300 Drive Axle Service Manual PLUG AND ELASTIC STOP NUT TORQUE CHARTS 5 16 24 O RING PLUGS P N LBF FT 3 8 24 7 16 20 1 2 20 9 16 18 3 4 16 7 8 14 1 1 16 12 1 3 16 12 1 5 16 12 15 8 12 1 7 8 12 1 16 27 PLUGS Size NPTF LBF FT 1 8 27 1 4 18 3 8
26. Heat and install bearing cones on differential body halves 67 48T300 Drive Axle Service Manual Lam Figure 230 Figure 233 Apply a heavy coat of grease or petroleum jelly to the Load second row of 29 needle rollers inside diameter of differential pinion gear The grease is used to hold needle rollers in position in following steps Figure 231 Figure 234 Load 29 needle rollers into one Install inner and outer bearing spacers and end of differential pinion gear bore install gear onto spider NOTE See figure 235 for proper spacer usage and positioning Figure 232 Figure 235 Install center bearing spacer Proper bearing spacer usage and positioning 68 48T300 Drive Axle Service Manual Figure 236 Lubricate and install differential thrust washer Repeat steps in figures 230 236 for remaining 3 differential pinion gears Figure 237 Lubricate differential side gear with axle lubricant Figure 238 Set the differential spider with gears in the differential body bores and side gear teeth 69 Figure 239 Align tangs on 4 pinion thrust washers with counter bore in differential body as shown Figure 240 Lubricate pinion gear teeth with axle lubricant Figure 241 Set side gear onto differential pinion gears 48T300 Drive
27. Manual Figure 170 Install friction disc Alternately install the remaining reaction and friction discs NOTE Align the friction disc oil grooves missing teeth with the previously installed friction disc Alignment of friction disc teeth at this time will ease spline engagement during hub installation Figure 171 Line up the reaction disc teeth with the internal teeth in brake housing Figure 172 Install 2 alignment pins in brake housing 180 apart NOTE Alignment pins can be made by using bolts with heads cut off Piston Installation Figure 173 Install outer piston seal assembly Figure 174 Install inner piston seal assembly NOTE Use caution not to over stretch the inner o ring and seal ring F il n m 5 E 15 3 ze Figure 175 Lightly lubricate inner and outer piston seals and piston with grease install piston in brake cover 57 48T300 Drive Axle Service Manual Figure 176 Evenly press piston into brake cover until it bottoms out C clamps can be used as shown to ease this process Cover Installation Figure 177 Install 2 pressure port seal rings NOTE Use grease to retain seal rings in grooves during handling and assembly N 7 Figure 178 Mark location of pressure ports brake cov
28. ONS WITH POSI STOP BRAKE 1 Before wheel bearing adjustment is made it is imperative all tapered bearing cones and cups be pressed to fully seated position Do not attempt to seat cups and cones by tightening spindle nut against internal gear hub as this is not an effective method of seating the components and damage may occur 2 Coat face of spindle nut spindle threads and splines with Anti Seize or Never Seez 3 Install spindle nut and tighten to 1200 LBF FT 1627 Nm Shock internal gear hub with heavy bar while rotating wheel hub a minimum of 2 revolutions Recheck nut torque if nut moves re torque to 1200 LBF FT 1627 Nm and repeat shocking and rotating Repeat process until the spindle nut does not advance when tightened 4 Loosen the spindle nut to turn and shock the wheel hub until a slight amount of bearing end play is achieved and the wheel hub can rotate freely 5 Using a strap hoist and scale or torque wrench and adapter bar determine the rolling torque of the wheel end with the bearings in a no load condition Due to the imbalance of the hub assembly there will be a variation in rolling torque as the wheel hub is rotated Record the maximum rolling torque figure observed while the hub is being rotated This figure will be the No Load rolling torque 6 The acceptable no load value should be between 10 50 LBF FT 14 68 Nm If higher than this open brake bleeder rotate hub and shock brake to release brake If brake do
29. Regardless of the method check the cup s final seating against the housing shoulder with feeler gauges Take extreme care that standard product bearings are never heated above 1499 C 300 F If bearings are heated above this temperature their metallurgical structure may soften rendering them unsuitable for use There are a number of recommended methods for heating bearings Electric ovens or electrically heated oil baths may be used but only when accompanied by proper thermostatic control If you use a hot plate to heat the oil never rest bearings directly on the bottom of the pan Instead protect bearings from the heat source with a simple wire screen holder or similar device Use heat resistant gloves to handle heated cones Hold the hot cone solid against the cold shoulder on the shaft until the cone grabs on to the shaft The hot cone will pull away from the cold shoulder unless it is held in position Use 002 05 feeler gages to make sure the cone is fully seated against the shoulder after the parts are cooled Many loose bearing settings excessive end play are caused by an unseated cone working back against the shoulder in service 14 48T300 Drive Axle lt gt Service Manual CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and fo
30. SPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAINING RINGS Replacement of spring loaded oil seals gaskets and snap rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing member should be handled carefully particularly when being installed Cutting scratching or curling under lip of seal seriously impairs its efficiency At reassembly lubricate lips of oil seals with Multipurpose Lithium grease Grade 2 15 481300 Drive Service Manual CLEANING AND INSPECTION CONT GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gea
31. Service Manual SPICER Off Highway Products Industrial Planetary Axles Heavy Planetary Rigid 481300 ASM 0117 August 2008 48T300 Drive Axle Service Manual TE 481300 Drive Service Manual FOREWORD This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Products Extreme care has been exercised in the design and selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product it s principle of operation troubleshooting and adjustments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana Important Always furnish ser
32. The brake cover is under 72 000 psi pounds square inch of pressure created by the brake apply springs It is recommended that the capscrew heads be numbered to assist in following the loosening tightening sequence Refer to figure 63 In a crossing or star pattern loosen the 24 brake cover capscrews turning no more than one quarter 1 4 turn at a time in sequence Continue this process until all pressure on the cover has been relieved 48T300 Drive Axle Service Manual Figure 63 After all spring force has been relieved from cover remove the 24 cover screws and washers Figure 64 Install 2 eye bolts to assist in handling the brake cover in opposite warning plate holes Figure 65 Remove brake cover 38 Discs Pressure Ring and Spring Removal LU RA Figure 66 Remove brake friction and reaction discs NOTE If discs are to be reused they need to be reinstalled in the exact order and direction in which they were removed 4 Figure 67 Remove brake piston pressure ring Figure 68 Remove brake springs NOTE Inner and outer springs are matched sets and must remain together As each set is removed it is recommended that they be wired together to prevent mixing sets 48T300 Drive Axle Service Manual Figure 69 Remove brake cover seal ring Wear Indicator Pin Removal
33. When heat is not used pack dust shield cavity with grease Figure 282 Apply bead of RTV sealant as shown centered over joint between shaft splines and flange splines Figure 283 Install input shaft nut and washer 76 48T300 Drive Axle Service Manual C uy i Figure 284 Figure 286 Tighten input flange nut to Compare ring gear convex tooth pattern with right 525 560 LBF FT 712 759 Nm hand gear tooth contact chart on page 24 Follow instructions on chart to correct pattern problems Checking Ring Gear Contact Pattern Figure 287 Compare ring gear concave tooth pattern with right Figure 285 hand gear tooth contact chart on page 24 Follow Paint 6 to 8 ring gear teeth with gear contact instructions on chart to correct pattern problems checking compound as shown While turning input shaft initiate a load on the differential body and ring gear with a length of 2x4 wedged between the differential body and carrier housing Rotate input so the pinion gear teeth make several passes through the checking compound in each direction Figure 288 Install input flange nut cotter pin and bend ends as shown 77 48T300 Drive Axle Service Manual Thrust Screw Installation Figure 292 Tighten thrust screw lock nut to 350 LBF FT 475 Nm NOTE Observe position of thrust screw
34. al Input Flange Spacer Installation CHAMFER W R E 8 Figure 272 Install input flange Spacer NOTE Assemble with chamfer towards bearing cone Carrier Cover Installation m Figure 273 Apply a continuous 06 1 5 mm diameter bead of RTV sealant to carrier cover mounting surface Figure 274 Using appropriate driver install input seal in carrier cover NOTE Position seal with the dust lip facing out 72 Figure 275 With the aid of an alignment pin install carrier cover iu nil i ss LI TE Figure 276 Apply Loctite 262 or equivalent to carrier cover screws Figure 277 Install 9 carrier cover screws with lock washers NOTE Do not install cover screws at this time in the two hole shown above if using a chain to install differential assembly Reattach chain as shown in axle disassembly figure 42 48T300 Drive Axle Service Manual Figure 278 Tighten cover screws to 65 70 LBF FT 88 95 Nm Input Flange Installation Figure 279 Pack input shaft oil seal with grease and apply heavy coat to outer lip Figure 280 If replacement is required install input flange dust shield using appropriate driver Figure 281 Install input flange NOTES The flange splines are an interference fit which require that the flange be heated or driven on shaft
35. alf bearing cone Clean and inspect all components Repair or replace components as required 48T300 Drive Axle Service Manual REASSEMBLY Planetary Reassembly Figure 140 Locate thrust washer chamfer as shown Figure 141 Using appropriate driver install washer in planet carrier TE Figure 142 Identify large radius on bearing race as shown Gear and bearing assembly must be assembled with radius facing towards planet carrier Figure 143 Heat gear and bearing assembly to aid assembly Install with the bearing radius down Refer to bearing heating and freezing guidelines on page 14 Ww fir 5 E Figure 144 Install retaining ring T Figure 145 Repeat steps in figures 142 144 for remaining 3 assemblies 52 48T300 Drive DANAS Service Manual Hub Reassembly d u Figure 149 F Eu 4 Figure 146 Lubricate inner cone with axle lubricant and install Install inner and outer bearing cups Tips for installing cups can be found in bearing heating freezing guidelines page 14 Figure 150 Apply continuous coat of Loctite 262 Figure 147 equivalent to outside diameter of hub seal Using a 002 feeler gage check that bearing cups Insure entir
36. brake housing 9 Install first steel reaction plate in pressure plate 10 Install first friction disc and lining assembly in pressure ring and against first steel plate 11 Install second steel reaction ring 12 Install second friction disc aligning the four 4 oil grooves in the second disc with the oil grooves in the first friction disc 13 A Alternate steel plates and friction discs until five 5 plates and five 5 discs are installed First plate installed is steel and last disc installed is friction NOTE Always align friction disc oil grooves and careful alignment of friction disc teeth at this time will facilitate wheel hub spline alignment in discs at wheel hub assembly in brake 14 Install a new square cut sealing ring in groove in brake housing 15 Position brake cover on brake housing aligning fluid hole marks on cover with holes in housing Refer to Posi Stop brake reassembly on page 56 16 Install cover to housing bolts and washers If there is a slight gap between cover and housing carefully and evenly tighten bolts to specified torque 17 Carefully and evenly loosen bolts in compression tool When bolts are away from compression cylinder remove spindle nut Remove compression tool and cylinder from spindle and brake 94 SPRING COMPRESSION TOOL WELDMENT 48T300 Drive Axle Service Manual SS3NQUuVH 32 48405 Sr OFr OL didW3l ONY HONANO LY34L LV3H 2 H2289 H2298 HO29
37. carrier Figure 102 Remove outer bearing retainer and shims Figure 104 Remove remaining 5 drop gear access cover screws lock washers and cover Figure 103 Remove 2 top corner drop gear access cover screws and install alignment pins NOTE Alignment pins can be made by removing heads from bolts Figure 105 Reinstall input flange nut to protect threads from damage Fi WT 42 Figure 106 Tap end of input and drop gear shaft to release pressure on the bearing retaining snap ring 48T300 Drive Axle Service Manual Figure 107 Remove bearing retaining snap ring NOTE Input and drop gear shaft not as shown Figure 108 Drive input and drop gear shaft out of inner bearing cone The outer input shaft bearing cup will also be pushed out of the carrier during this procedure NOTE Input and drop gear shaft not as shown Figure 109 Remove input and drop gear shaft NOTE Input and drop gear shaft not as shown 46 Figure 110 Remove input and drop gear shaft outer bearing cone NOTE Input and drop gear shaft not as shown Figure 111 Remove input drop gear bearing and snap ring washer Pinion and Drop Gear Removal Figure 112 Remove pinion nut cotter pin 48T300 Drive Axle Service Manual Figure 113 Figure 116 R
38. ce Rolling torque should be between 10 50 LBF FT 14 68 Nm If higher open brake bleeder rotate hub and shock brake to release brake If brake doesn t release apply 3 PSI 21 kPa to cooling cavity of brake with bleeder open Record no load value Tighten spindle nut until 1st of 3 pairs of holes in lock plate line up with tapped holes in internal hub 85 48T300 Drive Axle Service Manual Figure 333 Check rolling torque of hub This value should be 50 80 LBF FT 68 108 Nm over the no load reading recorded in step on figure 329 If reading does not fall within specification refer to wheel bearing adjustment procedure items 7 or 8 on page 19 Brake Cavity and Seal Air Test Figure 334 Perform brake cavity and seal air test using a gauge shut off valve and regulator as shown or equivalent Apply 12 PSI 83 kPa to brake through the cooling port and close valve Brake must hold 12 PSI 83 kPa for 15 seconds with no drop in pressure If leaks occur determine cause repair and retest Figure 335 Remove air test plumbing and install brake cooling port plugs Tighten inlet plug to 30 35 LBF FT 41 47 Nm and outlet plug to 45 50 LBF FT 61 68 Nm w Figure 336 Release hydraulic pressure to brake actuating port and remove hydraulic plumbing Install brake actuating port plug and tighten to 20 25 LBF FT 27 34 Nm
39. e surface is covered are seated against the shoulder When cup is CAUTION Do not over apply seated feeler gage should not fit between cup and hub shoulder Check in several locations Figure 151 Figure 148 Use seal driver to install seal Lubricate bearing cup with axle lubricant Refer to tool drawing on page 102 53 48T300 Drive Axle Service Manual Internal Ring Gear and Hub N Assembly and Installation Refer to exploded view and parts description on pages 5 and 6 for this procedure Figure 152 Install internal gear hub Item 27 mE Figure 155 in internal ring gear Item 26 Install internal ring gear snap ring Item 28 NOTE Internal ring gear and hub assembly not as shown Figure 153 Figure 156 Heat inner bearing cone and install on internal gear hub Install 2 screws with large flat washers as shown Refer to bearing heating and freezing guidelines on page 14 Lightly tighten screws until washers contact hub NOTE Internal ring gear and hub assembly not as shown E LE gem 4 Figure 154 Figure 157 Lubricate inner bearing cone with axle lubricant Install lifting device NOTE Internal ring gear and hub assembly not as shown Refer to tool drawing on page 99 54 48T300 Drive Axle Service Manual Posi Stop Brake Reassembly
40. emove pinion nut and washer Remove outer pinion bearing cone and spacer ge 2 Figure 114 Figure 117 Install pinion removal tool as shown Remove pinion Refer to tool drawing on page 101 OPTIONAL Reinstall pinion nut to protect threads and carefully drive pinion out of bearing 4 U E Figure 118 Figure 115 Remove inner bearing Press pinion out of outer pinion bearing cone 47 48T300 Drive Axle Service Manual c E Figure 119 Figure 122 Remove pinion drop gear Inner pinion bearing cup removed with shims y in E d TP adu PR Fa Figure 120 Figure 123 Remove outer pinion bearing cup Remove inner input and drop gear shaft bearing cup Ring Gear Removal Figure 121 Figure 124 Remove inner pinion bearing cup Remove 12 ring gear nuts 48 48T300 Drive Axle Service Manual Figure 128 OPTIONAL To facilitate removal of differential body screws apply heat to release thread locking compound Be careful not to overheat or discolor unit ia Figure 125 Remove 12 ring gear screws using a punch as shown NOTE Use energy absorbing material like the wood blocks shown to protect the ring gear teeth The ring gear shou
41. er and housing Align ports and install cover on alignment pins Figure 179 Remove 2 alignment pins and install 24 brake cover screws and washers NOTE Run screws down only Finger Tight E 40 x Figure 180 Mark screws with numbers from 1 24 in a criss crossing pattern P Figure 181 Carefully recheck alignment of reaction disc teeth and teeth in the brake housing IMPORTANT This is a critical step If the teeth are not properly aligned they will not enter the brake housing without damage as the springs are compressed 48T300 Drive Axle Service Manual Figure 182 Tighten the 24 brake outlet cover screws in a criss crossing pattern by turning each screw NO MORE THAN 1 4 TURN As springs are compressed check alignment of reaction disc teeth as they enter the brake housing When cover contacts brake housing the screws should be tightened to 175 190 LBF FT 240 260 Nm a Figure 183 Install 2 pressure port plugs Tighten to 84 120 LBF IN 10 14 Nm 1 Figure 184 Air pressure test Refer to pressure test instructions on page 21 Figure 185 Hydraulic pressure test brake Refer to pressure test instructions on page 21 Figure 186 One at a time remove the 24 brake cover screws Apply Loctite 262 or equivalent to the threads reinstall and tighten to 175 190 LBF FT 240 260 Nm
42. esn t release apply 3 PSI 12 kPa to cooling cavity of brake with bleeder open Record no load value NOTE The specifications given are for axles using new parts For service on axles with used parts the procedure is the same except the minimum allowable rolling torque can be as low as 5 LBF FT 7 Nm 7 Tighten spindle nut to 600 LBF FT 813 Nm Advance the nut until 3 pairs of holes in the lock plate line up with the holes in the internal gear hub 8 Check wheel hub rolling torque it must be within the specified range as listed below If rolling torque is higher than specified reduce the nut torque to obtain an acceptable reading but not less than 400 LBF FT 542 Nm If spindle nut torque must be reduced below 400 LBF FT 542 Nm there is likely a concentricity or alignment issue in the hub assembly and it should be disassembled and inspected and reassembled as required 9 If rolling torque is lower than specified increase spindle nut torque until preload is in specified range with lock plate holes aligned Do not torque to more than 1400 LBF FT 1898 Nm Recheck rolling torque after rotating the wheel hub at least 5 times 10 Install lock plate and screws and tighten to 35 40 LBF FT 47 54 Nm Note Bearing preload should be 50 80 LBF FT 68 108 Nm over no load 19 481300 Drive Service Manual FACE SEAL INSTALLATION INSTRUCTIONS 1 Clean wheel hub and brake housing bores with solvent prior to installat
43. etainer Reference figures 220 222 STEP 5 Using a dial type torque wrench measure the rolling torque of the input shaft assembly and record value STEP 6 Subtract value in step 2 from value in step 5 The correct result should be 27 41 LBF IN 3 5Nm If the result is not within this range repeat steps 4 6 adding or subtracting 002 0 050mm thickness shims until the desired rolling torque is obtained EXAMPLE 47LBF IN 5 3Nm Value from step 5 17 LBF IN 1 9Nm No load value from step 2 30 LBF IN 3 4Nm Must be within 27 41 LBF IN 3 5Nm 66 48T300 Drive Axle Service Manual A EI 4 es zi 3 o ir 1 Figure 224 Remove 4 retainer screws and lock washers Figure 227 Apply Loctite 262 or equivalent to 8 input shaft bearing Install 4 differential outer clutch retainer screws assemble with lock washers and tighten discs into differential flanged half to 65 70 LBF FT 88 95 Nm Remove input flange nut Differential Body Assembly Figure 228 EM Figure 225 Install 3 differential inner clutch discs onto side gear Clean cured thread locking compound from differen tial plain half screw holes with a 625 11 UNC 3B tap and clean holes of any remaining residue Figure 229 Install side gear with clutch discs di into differential body flanged half
44. flats before torquing to be sure screw did not turn with nut Figure 289 Apply teflon thread sealer to thrust screw L m Figure 290 Install thrust screw and nut Tighten screw until it contacts ring gear Figure 291 Using a dial indicator as shown back out thrust screw 010 015 25 38 from contact with ring gear 78 48T300 Drive Axle Service Manual Spindle and Brake Installation Figure 296 Install alignment pin in upper spindle screw hole Figure 293 NOTE Threaded end of pin must engage threads Apply grease to spindle housing seal ring and install in axle housing a minimum of 1 5 times pin diameter or 2 0 50 8 mm m 4 hs Figure 294 Figure 297 Apply grease to spindle pilot seal ring and install Install Spindle NOTE Spindle pilot needs to be fully engaged in axle housing A soft mallet may be necessary to drive spindle into position Figure 295 i Clean taped holes with solvent and compressed air Figure 298 IMPORTANT Remove top screw from brake and install lifting device Do not clean chase threads using a tap Refer to tool drawing on page 99 Apply grease to spindle pilot bore in axle housing 79 48T300 Drive Axle Service Manual Figure 299 Figure 302 Apply grease to brake seal ring and install Install 12 spindle scre
45. ge NOTES The flange splines are an interference fit which require that the flange be heated or driven on shaft When heat is not used pack dust shield cavity with grease Input and drop gear shaft not as shown 91 48T300 Drive Axle Service Manual Figure 368 Apply bead of RTV sealant as shown centered over joint between shaft splines and flange splines NOTE Input and drop gear shaft not as shown Figure 369 Install flange washer and nut Tighten output flange nut to 525 560 LBF FT 712 759Nm Figure 370 Install output flange nut cotter pin and bend ends as shown 92 Figure 371 Install 2 oil level plugs and tighten to 30 35 LBF FT 41 47 Nm Axle Air Pressure Test Figure 372 Remove cooling drain plugs from both brakes Remove 1 planetary or axle housing plug and install a gauge shut off valve and regulator or equivalent as shown Apply 12 PSI 83 kPa to pressurize the complete axle assembly and close shut off valve Axle must hold 12 PSI 83 kPa for 15 seconds with no drop in pressure If leaks occur determine cause repair and retest Remove air test plumbing and reinstall plugs Refer to axle pressure test instructions on page 22 48T300 Drive Axle ADANA Service Manual BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS WARNING DO NOT ATTEMPT TO MAKE ANY REPAIRS ON THE BRAKE UNTIL THIS TEXT IS COMPLETELY READ AND UNDERSTOOD AND
46. h specification is 010 015 250 380 mm Adjustment is made by loosening adjusting nut on one side and tightening opposite nut a corresponding amount until the correct backlash is achieved After obtaining correct backlash recheck tightness of adjusting nuts to assure that all clearance has been removed from differential bearings Figure 264 Remove 4 cap nuts apply Loctite 262 or equivalent and reinstall Figure 265 Tighten cap nuts to 475 525 LBF FT 645 710 Nm 48T300 Drive Axle Service Manual Figure 266 Apply Loctite 262 or equivalent to 2 differential adjusting nut lock screws Figure 269 Install 2 alignment pins in top corner holes Figure 267 Install 2 differential adjusting nut lock screws and z washers Tighten to 15 18 LBF FT 20 24 Nm Figure 270 NOTE Select the screw hole that does not cause Install access cover on alignment pins Apply Loctite the screw to interfere with the adjusting nut lugs 262 or equivalent to 6 cover screws and install with lock washers Remove 2 alignment pins and install Drop Gear Cover Installation remaining screws and lock washers Figure 268 Apply a continuous 06 1 5 mm diameter bead of Figure 271 RTV sealant to drop gear access cover mounting surface Tighten cover screws to 25 28 LBF FT 34 38 Nm 74 48T300 Drive Axle Service Manu
47. ial and model numbers when ordering parts SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damaged the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part Do not use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of purpose designed tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither his safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may damage the unit or render it unsafe It is important to understand that these Cautions and Notices are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions 48T300 Drive Axle Service Manual Page CON AU PR 10 12 13
48. ide clamps over base of micrometer With the thumb screws reacting on base secure micrometer IMPORTANT The micrometer extension must pass freely through the micrometer bar guide bore and base of the micrometer must rest on the micrometer arbor when mounted Mount adapter discs on micrometer arbor and set in position in carrier housing Exercise care to be sure that micrometer and extension do not contact any part of the carrier in this operation Apply pressure by hand and rotate adapter discs slightly to obtain a contact with bearing surfaces Remove checking gauge assembly and check for full bearing contact on bearing surfaces If contact is full and proper again position checking gauge assembly in carrier and check distance to ground surface on pinion Do not apply pressure to arbor or micrometer Turn micrometer carefully and evenly until the flat tip of the micrometer extension contacts the ground surface of the pinion squarely Subtract this reading from the value previously recorded and this equals the amount of shims to be added between the inner pinion bearing cup and the carrier housing EXAMPLE 5 289 134 341 Value etched on ring gear 0 469 011 913 mm Constant 1 2 thickness of gauge bar 5 758 146 253 mm Total 5 728 145 491 mm Initial micrometer reading 0 030 762 mm Add this value in shims under inner pinion bearing 18 48T300 Drive Axle DANA Service Manual ug WHEEL BEARING ADJUSTING INSTRUCTI
49. ilize for 30 seconds This is to compensate for temperature change piston movement and seating of seal lips C Re pressure to 12 PSI 83 kPa if required and hold for 15 seconds with no pressure drop Repeat re pressuring until 12 PSI 83 kPa holds for 15 seconds minimum but not over 3 repressurings E If after 3 re pressurings brake will still not hold pressure tear down and determine cause of leak rebuild and retest 2 Air and Hydraulic Pressure Test A After completing assembly with bleeder plugged apply 100 PSI 689 kPa air pressure to the brake fluid actuation port Shut off air at inlet to hold pressure on brake Brake should maintain pressure for 30 seconds without drop B Apply 1500 50 00 PSI 10342 344 000 kPa hydraulic pressure using mineral oil to brake actuation port shut off pressure at inlet to hold pressure on brake Inspect to insure that pressure plate has moved against housing stop and that friction discs are released and free Maintain pressure for 30 seconds minimum without drop Repeat twice If brake will not maintain pressure tear down and determine cause of leak rebuild and retest 21 481300 Drive Service Manual AXLE PRESSURE TEST INSTRUCTIONS If brake assembly is disassembled or partially disassembled the pressure apply fluid actuation test must be performed per the Brake Pressure Test Instructions If brake assembly is not disassembled or partially disassembled before mounti
50. ines where extra long maintenance intervals are required Braking action of the Posi Stop LCB is achieved through the application of the hydraulic piston and brake apply springs with the rotating friction surfaces which react with stationary stator plates The stator plates are retained by scalloped tangs at the outside diameter which in turn transfer the reaction torque to the rigid outside housing Hub splines are long enough to engage all friction discs before bearings or seals are set This provides ease of service reassembly Wheel bearings are serviced as in any normal bearing service procedure 48T300 Drive Axle Service Manual AXLE ASSEMBLY EXPLODED VIEW 48T300 Drive Axle Service Manual AXLE ASSEMBLY PARTS DESCRIPTION Item Description Qty 1 Cotter Pin Input amp Drop Gear Shaft Nut 1 2 Nut Input amp Drop Gear Shaft Flange 1 3 Washer Input amp Drop Gear Shaft 1 4 Flange Input amp Drop Gear Shaft Output 1 5 Shield Output Flange Dust 1 6 Oil Seal Input amp Drop Gear Shaft 1 7 Nut Bearing and Seal Retainer 7 8 Lockwasher Bearing and Seal Retainer 7 9 Stud Bearing and Seal Retainer 7 10 Retainer Bearing and Oil Seal 1 11 O Ring Bearing and Seal Retainer 1 12 Bearing Roller 1 13 Spacer Bearing 1 14 Bearing Roller 1 15 Plug Axle Ho
51. ing procedure on page 18 Lubricate inner pinion bearing cup with axle lubricant 60 48T300 Drive Axle Service Manual Figure 194 Position pinion drop gear in housing aligning hole in gear with bore in housing Pinion Gear Installation and Preload Figure 195 Heat and install pinion shaft inner bearing Refer to bearing heating and freezing guidelines on page 14 Figure 196 Install original pinion shaft inner bearing spacer if ring and pinion or drop gear was not replaced See service parts list for spacer and shim kit to be used with new ring and pinion and or drop gear Follow the instructions supplied with the kit for proper usage and assembly of spacer and shim kit 61 Figure 197 Install pinion in housing and drop gear Figure 198 Secure pinion in position with a holding device similar to one shown Figure 199 Install original pinion shaft outer bearing spacer if ring and pinion or drop gear was not replaced See service parts list for spacer and shim kit to be used with new ring and pinion and or drop gear Follow the instructions supplied with the kit for proper usage and assembly of spacer and shim kit 48T300 Drive Axle Service Manual Figure 200 Figure 203 1727 e Tighten pinion nut to 525 560 LBF FT 712 759 Nm ubricate outer pinion bearing cup with axle lubrican
52. ion of the seal 2 Keep original mated metal sealing rings as set for wheel hub and brake cover DO NOT INTERMIX METAL RINGS All parts of seal should be free of grease oil dirt and scale 4 Sealing rings must be handled with care Lapped sealing faces must not be damaged scratched or contaminated with dirt or grease When installing the rubber toric the seal ring make sure that it is uniformly seated on the retaining lip and is not twisted Place the seal in the installation tool and locate this assembly squarely against the housing Use sudden and even pressure against the tool to push the toric under the retaining lip of the housing cavity Insure that the toric is uniformly captured under the housing cavity retaining lip and is not twisted or pinched The seal ring face should be parallel to the housing within 040 1 0 6 After installing the seal halves into the wheel hub and brake housing wipe both metal sealing surfaces clean with lint free cloth Then apply a coat of clean MS8 oil to the metal seal faces with a lint free applicator Oil must not wet surfaces other than sealing faces 20 48T300 Drive Axle DANA Service Manual ug POSI STOP BRAKE PRESSURE TEST INSTRUCTIONS 1 Air Pressure Decay Test and Criteria A After completing assembly and with bleeder plugged apply 12 PSI 83 kPa air pressure to the brake fluid actuation port Shut off air at inlet to hold pressure on brake B Let pressure stab
53. ld fall onto this material after a number of the screws are removed If it does not tap gear with a soft mallet Figure 129 Remove 12 differential body screws and washers Figure 126 Ring gear after dropping onto protective wood blocks Differential Disassembly Figure 130 Separate differential halves Figure 127 Mark differential case halves to identify for reassembly 49 48T300 Drive Axle Service Manual Figure 131 Remove inner and outer differential clutch discs Remove differential pinion thrust washers and outer bearing spacers Figure 132 Figure 135 Remove side gear Remove differential pinion gears needle rollers inner and center bearing spacers ES I Sie Figure 133 Figure 136 Remove differential spider pinion Remove side gear from differential body flanged half gear assemblies and thrust washers 50 48T300 Drive Axle Service Manual Figure 137 Remove inner and outer differential clutch discs from differential body flanged half gt E ri Figure 138 OPTIONAL Apply heat to facilitate removal of plain half bearing cone em FS Figure 139 Remove plain half bearing Repeat steps in figures 138 8 139 to remove flanged h
54. levels of ingested water in the axle or water as a result of condensation should not use extended drain intervals Friction Modifiers Friction modifiers may be used with the lubricant to reduce Posi Torq limited slip differential noise or liquid cooled brake noise If friction modifiers re used follow instructions on TSB 278E The use of aftermarket lubricant additives other than those specified is not recommended and may reduce the life of the axle and void the warranty Recommended Viscosity Grade Based on Prevailing Ambient Temperature 13 481300 Drive Service Manual BEARING HEATING AND FREEZING GUIDELINES Bearings often must be cooled or heated to aid in assembly or removal Since temperature extremes can cause permanent bearing metallurgical damage it is important to take proper precautions and use correct methods when heating and cooling bearings Cups that are to be assembled in hubs or housings with a press fit may be shrunk in a deep freeze unit Standard class bearings should not be cooled below 65 F 54 In addition to cooling the bearing cup in some instances it may be necessary to heat the housing To control temperature is best to use a thermostat along with a freezer unit or a properly calibrated thermometer If a suitable freezer or thermometer is not available your Timken service representative can suggest liquid combinations that freeze the bearing cup at the optimal temperatures
55. n discs 9 Cautiously and evenly turn out a thread at a time the compression tool bolts The compression springs will push the piston pressure ring out of the brake housing WARNING BEFORE REMOVING COMPRESSION TOOL FROM SPINDLE MAKE SURE ALL SPRING FORCE IS OFF OF PRESSURE RING AND RING MOVES FREELY IN BRAKE HOUSING 10 Remove spindle nut and remove two piece compression tool Refer to pages 37 amp 56 for detailed disassembly and reassembly instructions for servicing the internal components of the brake housing and cover 481300 Drive Service Manual BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS CONT REASSEMBLY 1 Install brake housing on axle 2 Install all spring sets 3 Position piston pressure ring in brake housing 4 Install spring compression tool main section over axle spindle and centered in pressure ring 5 Install the bolt plate and bolts over the spindle Back the bolts out far enough so they do not contact the cylinder face 6 Install spindle nut and tighten securely against round compression tool 75 Turn the four 4 compression tool bolts in against compression tool cylinder 8 Cautiously and evenly a criss crossing manner tighten compression tool bolts a thread or two at a time to compress spring sets and push pressure ring into brake housing Springs are compressed far enough when the tangs on the pressure ring are approximately 1 8 of an inch from being flush with face of
56. nal ring gear assembly not as shown 1 Figure 53 Remove bearing cone using punch as shown NOTE Internal ring gear assembly not as shown Figure 54 Remove hub seal as shown or drive bearing cone and seal out from other side 48T300 Drive Axle Service Manual Figure 55 Remove hub seal and bearing cone Figure 56 Remove outer wheel bearing cup nm Figure 57 Remove inner bearing cup 36 48T300 Drive Axle Service Manual Posi Stop Brake Disassembly Figure 58 Remove 4 warning sticker cover screws WARNEN ee EN SEE i p EL 3 Figure 59 Remove 2 warning sticker covers Note Warning Figure 60 Note warning cast into brake cover 37 Figure 61 Remove 2 pressure port plugs Brake Cover Removal Figure 62 This disassembly procedure is tedious and time consuming Due to the potential for injury and damage any shortcuts should be avoided A spring compression tool drawing and instructions are included on page 93 Itis recommended the compression tool be used to disassemble and reassemble the brake IMPORTANT If the brake spring compression tool is not going to be used the following procedure must be followed to avoid personal injury and component damage
57. ng Port Plug Cooling Outlet Port O Ring Cooling Outlet Port Plug Plug Cooling Outlet Port O Ring Cooling Outlet Port Plug O Ring Actuating Port Plug Screw Bleeder Housing Brake Spring Brake Apply Outer Spring Brake Apply Inner Sealing Ring Pressure Ring Pressure Ring Piston 0 PARTS DESCRIPTION Qty N A 10 Item Description 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Disc Reaction Disc Friction Sealing Ring Brake Cover Seal Assembly Piston Outer Piston Brake Seal Assembly Piston Inner Cover Brake Outer Sealing Ring Port Square Cut Sticker Warning Cover Sticker Capscrew Sticker Cover O Ring Port Plug Plug Port Washer Outer Cover Capscrew Capscrew Outer Cover Attaching Qty MeN Bens nN N RA PA Aa pam UI UI N 481300 Drive Axle DANA Service Manual PLANET EXPLODED VIEW AND PARTS DESCRIPTION Item Description Oty Item Description Oty 1 Snap Ring Planetary Gear Bearing 4 4 Carrier Planetary 1 2 Bearing PlanetaryGear iw 4 5 Washer SunGearThrust 1 3 Gear Planetary 11 48T300 Drive Axle Service Manual OIL CHECKING PROCEDURE Check lubricant level after each 250 hours of operation Always maintain lubricant level to bottom of filler plug hole Drain oil every 2 500 hours or within one year To check oil level in axles with differential drive and planetar
58. ng spacer will need to be replaced with a pinion bearing spacer and shim kit If the spacer and shim kit has already been installed adjustments to the shim EU pack are required See service parts list for spacer Figure 211 and shim kit identification Follow instructions Heat and position input shaft drop gear in housing supplied with the kit for proper usage and assembly IMPORTANT Immediately proceed to step in Repeat disassembly steps in figures 113 117 and figure 212 before drop gear and bearing cool reassembly steps in figures 196 208 63 48T300 Drive Axle Service Manual Figure 212 Install input shaft into drop gear and inner bearing cone 4 Figure 213 Install input shaft snap ring washer Figure 214 Install input shaft bearing retaining snap ring M Figure 215 Drive input drop gear shaft forward to remove all end clearance between snap ring snap ring washer bearing cone and to insure that bearing cup is seated in bore NOTE Be sure to protect end of shaft and threads from being damaged Figure 216 Heat input shaft outer bearing cone and install 48T300 Drive 1 Service Manual Figure 217 Figure 220 Position input outer bearing cup over shaft Position bearing retainer shims on alignment pin NOTE It is a good practice to start out with the same or
59. ng to axle no pressure apply fluid check is required Pressure test axle as follows A B J Remove drain plugs from both brakes Apply 12 PSI 83 kPa air pressure to complete axle Normally thru axle housing breather hole and shut air off at inlet to lock pressure on axle Axle must hold 12 PSI 83 kPa for 15 seconds with no drop in pressure If leaks occur determine cause rebuild and retest see 1 above also If no leaks occur make sure cooling ports are plugged apply 12 PSI 83 kPa air pressure to drain port of each brake shut off air at inlet to lock pressure on brake cavity Each brake cavity must hold 12 PSI 83 kPa for 15 seconds with no drop in pressure If leaks occur determine cause rebuild and retest starting at A see 1 above also 22 481300 Drive DANA Service Manual GEAR TOOTH CONTACT CHART LH MOVE PINION CENTER 77 GEAR IN THIS OIRECTION WL MOVE PINION AWAY FROM ADDENDUM PROFILE Z CONVEX DEDENDUM A SIOE MOVE GEAR AWAY FROM MOVE GEAR AWAY FROM PINION IN THIS DIRECTION PINION IN THIS DIRECTION ALL CONTACT BEARINGS SHOWN BELOW ON LEFT HAND SPIRAL RING GEAR THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH FIG 1 TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH WHILE UNDER A LIGHT LOAD FIG 2 TOE BEARING ON BOTH SIDES OF TOOTH GEAR SET NOISY TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AW
60. ntial Case 1 39 Gear Ring 1 40 Clutch Disc Differential Outer 8 41 Clutch Disc Differential Inner 6 42 Side Gear Differential 2 43 Spider Differential 1 44 Spacer Inner Bearing Roller 4 45 Roller Bearing 232 46 Spacer Center amp Outer Bearing Roller 8 47 Gear Differential Pinion 4 48 Washer Pinion Thrust 4 49 Plain Half Differential Case 1 50 Washer Differential Case Capscrew 12 51 Capscrew Differential Case 8 52 Capscrew Differential Case 4 53 Gear Pinion 1 54 Bearing Cone Pinion Inner 1 55 Bearing Cup Pinion Inner 1 56 Shim Pinion Bearing Cup 004 AR 57 Shim Pinion Bearing Cup 007 AR 58 Shim Pinion Bearing Cup 010 AR 59 Kit Inner Pinion Bearing Spacer amp Shim 1 60 Capscrew Diff Adjusting Nut Lock 2 61 Lockwasher Diff Adjusting Nut Lock 2 62 Cap Carrier 2 63 Assembly Differential Carrier amp Cap 1 64 Plug Drain 1 65 Gear Pinion Drop 1 66 Spacer Outer Pinion Bearing 1 67 Cup Outer Pinion Bearing 1 68 Cone Outer Pinion Bearing 1 69 Washer Pinion Nut 1 70 Nut Pinion 1 71 Cotter Pin Pinion Nut 1 lt gt 48T300 Drive Service Manual BRAKE EXPLODED VIEW gt Sn S SU 279 CU M e 25107 MAL gt SUSE 48T300 Drive Axle Service Manual Item 10 11 12 13 14 15 16 17 BRAKE Description Snap Ring Indicator O Ring Indicator Pin Pin Wear Indicator Non Serviceable Item Plug Actuati
61. or detailed instructions Figure 323 Apply Anti Seize or Never Seez lubricant to spindle threads entia Figure 326 Tighten spindle nut to 1200 LBF FT 1627 Nm while rotating hub Lifting strap and chain hoist are being used to rotate hub Figure 324 Install hub assembly It will be necessary to rotate wheel hub slightly to engage brake disc teeth Do not force as damage to disc teeth could occur Pr i F 222 SNL COM 3 1 4 B 7 oz H cs yy d Figure 327 Shock internal hub while rotating wheel hub After several revolutions retighten spindle nut to 1200 LBF FT 1627 Nm Repeat steps in figures 326 and 327 as many times as necessary until 1200 LBF FT 1627 Nm does not advance nut after shocking Figure 325 Install spindle nut After nut is secure on spindle remove lifting device and the screws and flat washers used for handling 84 48T300 Drive Axle Service Manual Figure 328 Figure 330 Loosen spindle nut 1 4 to 1 2 turn and shock hub Tighten spindle nut to 600 LBF FT 813 Nm until a slight bearing end play is achieved and the hub rotates freely Figure 331 Install spindle nut lock plate Figure 329 Check no load rolling torque of hub using a torque wrench and adapter bar or other appropriate measuring devi
62. r teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines HOUSINGS COVERS AND CAPS Inspect housings and covers to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures 16 48T300 Drive Axle DANA Service Manual ug AXLE REASSEMBLY The reassembly instructions describe the procedure to be followed when reassembling and installing components of the axle Instructions covering reassembly of opposite side are identical unless otherwise noted Important Class 8 8 10 9 12 9 grade 5 and grade 8 fastening hardware has been used in the production of the axle assemblies covered in the manual A table of proper torque values for the fastener classes above is provided within this manual The class of hardware may be determined by the markings contained on the head of each capscrew Class 12 9 or grade 8 torque values needs to be used on all socket head capscrews used with this assembly Torque values specified in the text of this manual are for class 8 8 10 9 12 9 grade 5 and grade 8 hardware were presently used in production On all axles being overhauled bolts and capscrews should be identified as described above and
63. reign materials CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners BEARINGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning Bearings may be rotated slowly by hand to facilitate the drying process HOUSINGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners Thoroughly dry all parts cleaned immediately by using moisture free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound IN
64. ring into the housing on 20 for detailed instructions i t 2 4 Figure 315 Figure 312 Carefully press 2nd half of face seal into wheel hub Clean face seal bore in wheel hub with solvent NOTE Use sudden and even pressure against tool to push the toric ring into the hub Figure 313 Figure 316 Install face seal and toric ring into installation tool Install hydraulic source to brake actuating port and Reference Caterpillar tool part number 8T7789 2 pressurize to 1500 PSI 10342 kPa to release brake 82 48T300 Drive Axle Service Manual Figure 317 Align brake friction discs so that the missing teeth wide space on all discs line up with each other Figure 318 Apply oil to face seal contact surface Figure 319 Apply oil to face seal contact surface Figure 320 Lubricate inner diameter of hub seal with oil Silver Grade Anti Serze Figure 321 Apply Anti Seize or Never Seez lubricant to spindle splines NOTE Refer to wheel bearing adjusting procedure on page 19 for detailed instructions 8 Figure 322 Apply Anti Seize Never Seez lubricant to face of spindle nut 48T300 Drive Axle Service Manual Wheel Bearing Preload Adjustment Refer to wheel bearing adjusting procedure on page 19 f
65. t gos Use pinion locking tool shown in figure 204 or equivalent to hold pinion from turning NOTE If original bearing spacer has been replaced with the pinion bearing spacer and shim kit apply Loctite 262 or equivalent to the pinion nut threads and tighten to 700 750 LBF FT 950 1017 Nm Figure 201 Using appropriate driver or by heating install pinion shaft outer bearing cone Figure 204 Pinion locking tool Refer to tool drawing on page 100 Figure 202 m Install pinion nut and washer Figure 205 Tap end of pinion several times with a soft mallet to seat bearings 62 48T300 Drive Axle Service Manual Figure 206 Tap carrier housing several times with a soft EE h s Pans mallet to seat bearings Refer to figure 203 m Figure 209 and recheck pinion bearing nut torque Install pinion nut cotter pin and bend ends as shown Input and Drop Gear Shaft Installation Figure 207 Remove pinion holding device 1 17 CIE Figure 210 Heat input shaft inner bearing cone and place into inner bearing cup in housing IMPORTANT Immediately proceed to steps in figures 211 amp 212 before bearing cools Figure 208 Check pinion bearing preload with a dial torque wrench Reading should be 5 30 LBF IN 6 3 4 Nm If reading is not within specification the original beari
66. torque value chart consulted for correct torque THREAD LOCKING COMPOUND Guidelines for application where to apply A Bolts capscrews and studs anchor end B Nuts apply compound to the male thread of the mating fastener C Apply compound to coat the full length and circumference of thread engagement D Remove excess compound from mating parts after fastener installation 17 481300 Drive Axle 2 DANA Service Manual PINION DEPTH SETTING PROCEDURE The function of the pinion setting gauge is to measure the distance from the centerline of the differential bearing bores to the ground surface on the gear end of the pinion This measurement when subtracted from the value etched on the ring gear will indicate the size of the shim pack required to position the pinion gear in proper relation to the ring gear On the outer diameter of the ring gear a ring gear to pinion distance will be etched add 4649 11 808 mm to it 4649 11 808 mm is half the thickness of the gauge bar Record this value This value may be different on each ring and pinion set due to manufacturing variations Use a file and emery cloth to remove all burrs and nicks from machined bearing surfaces of carrier housing Paint bearing surfaces with bearing contact checking compound Insert an extension depth micrometer Starrett 44B 6RC and extension 99347 7 178 mm or equivalent is recommended into the guide bore of the micrometer arbor and sl
67. using Filler 1 16 Non Serviceable Item N A 17 Screw Plate 2 18 Cap screw Planetary Mounting 6 19 Plug Planetary Level amp Drain 2 21 Planetary Assembly 2 22 O ring Planetary Assembly Sealing 2 23 Cap screw Adjusting Nut Lock 12 24 Lock Plate Wheel Bearing Adjusting Nut 2 25 Nut Wheel Bearing Adjusting 2 26 Gear Internal 2 27 Internal Hub 2 28 Snap Ring 2 Item Description Qty 29 Gear Sun 2 30 Cone Outer Wheel Hub Bearing 2 31 Cup Outer Wheel Hub Bearing 2 32 Hub Wheel 2 33 Seal Face 2 34 Cup Inner Hub Bearing 2 35 Cone Inner Hub Bearing 2 36 Oil Seal Hub 2 37 Cap screw Brake amp Spindle Mounting 26 38 Washer Brake amp Spindle Mounting 26 39 Retaining Ring Spindle 2 40 Brake Assembly 2 41 Sealing Ring Brake To Spindle 2 42 Spindle 2 43 Sealing Ring Spindle To Axle Housing 2 44 Sealing Ring Spindle Pilot 2 45 Shaft Axle 2 46 Housing Axle 1 47 Plug Magnetic Drain 1 48 Stud Differential Mounting 3 687 Long 2 49 Nut Differential Mounting 3 50 Washer Differential Mounting 14 51 Stud Differential Mounting 4 720 Long 2 52 Dowel Tapered Differential Mounting 4 53 Stud Differential Mounting 2 750 Long 10 54 Nut Differential Mounting 11 55 Differential Assembly 1 48T300 Drive Axle Service Manual DIFFERENTIAL AND CARRIER EXPLODED VIEW 48T300 Drive Axle Service Manual lt gt DIFFERENTIAL AND CARRIER PARTS DESCRIPTION
68. ws and washers Figure 300 Carefully install brake assembly Figure 303 Tighten 12 spindle screws to approximately 100 LBF FT 136 Nm Figure 301 Install spindle retaining ring Figure 304 Remove lifting device from brake 80 48T300 Drive Axle Service Manual Apply Loctite 262 or equivalent brake cover screw Figure 305 Figure 306 Install brake cover screw and washer Tighten to 175 190 LBF FT 240 260 Nm Figure 307 Remove alignment pin Install 1 spindle screw and washer Tighten to approximately 100 LBF FT 136 Nm Reference Figures 302 amp 303 Figure 308 Tighten 13 spindle screws to 1850 2000 LBF FT 2508 2712 Nm in a circular pattern Hub Installation Figure 309 Install lifting device on hub Figure 310 Screws and flat washers installed during hub reassembly should be in place as indicated above If not they should be installed to hold internal gear in hub during handling 48T300 Drive Axle Service Manual Face Seal Installation Figure 314 Figure 311 Carefully press face seal into brake housing Clean face seal bore in brake housing with solvent NOTE Use sudden and even pressure against NOTE Refer to face seal installation procedure tool to push the toric
69. y wheel ends the axle should be run first then allowed to stand for a minimum of five minutes on level ground This procedure will allow oil to drain back to its normal level After the five minute interval remove oil plug at axle center and in the planetary wheel ends for oil level inspection If oil level is not at the bottom of the filler hole add necessary lubricant CHECKING OIL LEVEL IN PLANETARY WHEEL ENDS Always check lubricant in planetary wheel ends with arrow on the planetary carrier face in the 6 00 o clock position Remove oil level plug if lubricant is below oil level hole add necessary lubricant DRAINING AXLE CENTER AND WHEEL ENDS Draining is best accomplished immediately after the vehicle has been operating The lubricant is then warm and will flow freely allowing full drainage in minimum time This is particularly desirable in cold weather Remove plug at bottom of axle housing and the filler plug on the planetary wheel ends making sure the planetary filler hole is down when draining Allow sufficient time for the lubricant to drain then replace plugs and refill with recommended lubricant When refilling be sure the arrow on the planetary carrier face is in the 6 00 o clock position allow the lubricant time to drain back to its normal level FLUSHING After draining axles should be flushed Replace drain plugs and fill axles to the proper level with a 2 diesel fuel Operate the vehicle for a short period of time in low

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