SERVICE MANUAL SALISBURY 5HA AXLES
Contents
1. TABLE AT2 MODEL TORQUE TO TORQUE TO TORQUE TO TURN TURN PINION TURN PINION AND COMPLETE AXLE WITH OIL DIFFERENTIAL A LBF IN B LBF IN C LBF IN 4HU 2 PIN 30 40 5 15 2 10 4HU POWER LOK 30 40 10 20 2 10 4HA 4HS 30 40 5 15 2 10 5HA 23 35 5 15 10HD 30 40 5 15 7DR 8DR 8HA 8HS 10HA 30 40 NOTE Torque B is additional to A and C is additional to B i e 35 at A 10 45 C 53Ibf in total 7DR 8DR 10DR Helical Ratio 1 4 2 0 2 0 2 6 2 6 4 4 Torque to turn helical Gears and Hypoid Pinion Ibf In Co E 1 Torque to turn hypoid pinion assy 15 20 Ibf In Primary input pinion bearing end float 0 002 0 005 SALISBURY TRANSMISSION LIMITED TABLE AT3 TORQUE TIGHTNESS Ibf ft MODEL DRIVE DRIVE DIFF BRG GEAR DIFF PINION GEAR CAP CARRIER CASE NUT BOLT BOLT COVER BOLT SCREW 4HA 4HU 34 UNF T 3 8 or 7 16 Ye UNC R 5 16 UNC S 3 8 UNC X UNF X 4HS 180 190 49 56 70 88 63 72 18 20 43 50 180 190 7 16 UNF X 63 72 3 8 UNC S 5 16 UNC W 70 88 29 33 23 26 7HA 5 8 UNF 3 8 UNF X 3 8 UNC T 5 16 UNC S 3 8 UNC X 95 105 49 56 32 36 18 20 43 50 8HA 10HA 7 8 UNF UNF X 1 UNC R 3 8 UNC S 7 16 UNC V 250 270 118 135 63 72 20 28 60 69 8HD 250 270 118 135 63 72 3 8 UNC R 60 69 26 30 TORQUE TIGHTNESS Nm MODE2. SERVICE MANUAL SALISBURY 5HA AXLES WINGET LIMITED P O BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODDER LANE BOLTON LANCS TEL 44 0 1204 854650 FAX 44 0 1204 854663 parts winget co uk service winget co uk www winget co uk Introduction Winget Limited gratefully acknowledge the assistance given by GKN Salisbury in the preparation of this manual however neither Winget Limited or Salisbury can be held responsible for any errors or omissions The procedures described within this manual should enable experienced service personnel to strip repair and re build Salisbury 5HA series axles fitted to Winget Site Dumpers in a safe and competent manner The procedures are not intended to be used by personnel who are unfamiliar with the product or mechanically inexperienced It is assumed that personnel are aware of the Health amp Safety Regulations which should be applied but the following should act as a reminder Whenever possible any repairs or service should be carried out in a clean environment If work must be carried out on site or in the field steps should be taken to ensure that dirt or foreign materials cannot enter the assembly Ensure all works tools are in good condition and only use the correct tool for the job in hand Always wear safety spectacles when using soft or hard faced hammers chisels drifts or when using air tools Wear safety spectacles when cleaning components or when grinding Do not misuse air li
3. bolts to torque figures as stated in table AT3 Check companion torque to turn figures as stated in table AT2 Re fit carrier cover using new gasket Tighten cover bolts to figure given in table AT3 Re fit half shafts axle shafts Re fill with oil of correct grade SECTION A 2 DISMANTLING AND REASSEMBLY OF AXLE CENTRE ASSEMBLIES USING COLLAPSIBLE SPACER This section covers certain 7HA AHA 4HU 8HA 8HS 8HD 10HA and 10HD centre sub assemblies DISMANTLING Drain oil and remove the halfshafts axle shafts 2 Remove carrier cover and gasket discard gasket figure AF1 3 Note markings on bearing caps a figure AF2 and axle casing b figure AF2 for use when refitting 4 Remove bearing caps using the loosened bolts to ease the caps away from the bearing c figure AF2 5 Remove any inclusions from stretcher holes d figure AF2 and rectify any damage on edges of holes in order that the carrier stretcher tool will fit correctly 6 Check turn buckle on carrier stretcher tool is free and fit tool to carrier ensuring that pegs locate fully in stretcher hole y Checking that no foul condition exists rotate turn buckle by spanner in order to stretch carrier IMPORTANT DO NOT STRETCH CARRIER MORE THAN 010 012 MEASURED ACROSS STRETCHER HOLE 8 Remove differential assembly complete with ring gear It may be necessary to lever the case out of the carrier In order to prevent damage do not lever aga
4. is necessary the cone may be withdrawn from the shaft by means of the extractor tool with suitable adaptor Fit the replacement bearing if required making sure that the cone is pressed squarely on the bearing diameter until it firmly abuts against the shoulder provided If the bearing is not pressed home it will creep in service resulting in excessive shaft endfloat which will damage the surfaces due to hammering Re assemble in reverse order ensuring inner shaft oil seal is not damaged when shaft is re fitted If new bearing is fitted ensure correct axle shaft endfloat 003 009 is obtained by the removal addition of shims from one axle end only Refit hub in accordance with Page C 1 N B New paper gaskets must be fitted when components are re assembled Re grease the assembly by means of the grease nipple SECTION F AXLE SHAFTS F 2 1 2 6a 10 10a 11 12 SEMI FLOATING OUTRIGGER Remove brake drum Remove hub in accordance with Page C2 Remove the bearing housing brake back plate mounting bolts Remove the brake back plate and the bearing housing taking care not to lose or damage any of the hub bearing adjusting shims which control the shaft endfloat Check oil seal as fitted into bearing housing for wear misplaced garter spring etc and replace is necessary Remove axle shaft complete with bearing cone To remove a broken axle shaft make a loop at one end of a length of stiff wire slid
5. ATING HUB 10 11 12 Remove axle shaft securing bolts discard tags if fitted Withdraw axle shafts discard gasket if not torn in removal Unbend locking tab on Tube Nut Locktab and remove both tube nuts Steadying Hub to keep in position withdraw outer Bearing Cone Pull off with gentle shock if necessary Hub Remove Inner Bearing Cone Examine Bearings Cups for signs of wear and replace both cup and cone if necessary Cut outs in the cup abutments are provided for drift access Removal of inner bearing cup will cause oil seal to be knocked out at the same time If an oil seal fault is suspected seal must be removed in this manner Examine oil seal for wear misplaced garter spring etc and re new if necessary Use smear of gasket sealant in either event The oil seal journal on the axle tube should also be examined If necessary press in replacement bearing cups preferably with the recommended Service Tool or on a hand press using convenient dollies which will not damage either bearing or bearing bore to ensure proper abutment The inner bearing must be inserted complete with cone liberally greased which will then be held in situ by the fitment of the oil seal Having greased oil seal journal carefully offer Hub onto tube end with gentle pressure until resistance is felt by bearing inner cone coming against its journal Gently tab hub home with soft hammer until bearing is hard against its abutment Note if gentl
6. ES SECTION C HUB ASSEMBLIES C 1 SEMI FLOATING HUB 1 Remove split pin 2 Unscrew shaft nut rectifying damage is necessary 3 Pull off hub using either conventional 3 leg puller or proprietary pullers engaging either on extractor thread or hub studs N B Shock treatment may be necessary in which case try a Striking opposite shaft end using soft hammer Or b Striking hub to be removed with blunt cold chisel in proximity of shaft key 4 Re assemble in reverse order being sure to smear anti scuffing paste rouge etc on shaft taper Replace shaft key if any sign of fretting causing loose fit Nut must be really tight Grease seal journal lightly with lithium based grease SECTION C HUB ASSEMBLIES C 2 SEMI FLOATING OUTRIGGER HUB 1 Remove split pin 2 Unscrew shaft nut rectifying damage is necessary 3 Pull off hub using either conventional 3 leg puller or proprietary pullers engaging either on extractor thread or hub studs N B Shock treatment may be necessary in which case try Striking opposite shaft end using soft hammer Or d Striking hub to be removed with blunt cold chisel in proximity of shaft key 4 Re assemble in reverse order being sure to smear anti scuffing paste rouge etc on shaft taper Replace shaft key if any sign of fretting causing loose fit Nut must be really tight Grease seal journal lightly with lithium based grease SECTION C HUB ASSEMBLIES C 3 FULLY FLO
7. HA 4HU 4HS 5HS 8HA 8HS 8HD 10HA and 10HD centre sub assemblies DISMANTLING 1 Drain oil and remove the halfshafts axle shafts 2 Remove carrier cover and gasket discard gasket figure AF1 3 Note markings on bearing caps figure AF2 and axle casing b figure AF2 for use when refitting 4 Remove bearing caps using the loosened bolts to ease the caps away from the bearing figure AF2 5 Remove any inclusions from stretcher holes d figure AF2 and rectify any damage on edges of holes in order that the carrier stretcher tool will fit correctly 6 Check turn buckle on carrier stretcher tool is free and fit tool to carrier ensuring that pegs locate fully in stretcher hole 7 Checking that no foul condition exists rotate turn buckle by spanner in order to stretch carrier IMPORTANT DO NOT STRETCH CARRIER MORE THAN 010 012 MEASURED ACROSS STRETCHER HOLE 8 Remove differential assembly complete with ring gear It may be necessary to lever the case out of the carrier In order to prevent damage do not lever against stretcher or carrier but use packing 9 Ease off turn buckle and remove spreader 10 Remove ring gear from differential case assembly if necessary 11 Remove bearing cones from differential case trunnion diameter if necessary 12 Disassemble differential in accordance with appropriate sheet 13 Prevent rotation of companion flange by using service tool having pegs locatin
8. IFFERENTIAL DISMANTLING OD Remove fixings and withdrawn crown wheel Mark the two halves so that alignment can be maintained on reassembly Remove the fixings and lift off the upper case Remove upper side gear and thrustwasher Lift out cross shaft 4 pinion mates and spherical thrustwashers Withdraw lower side gear and thrustwasher Remove differential bearing cones using extractor and press INSPECTION 8 Examine all components and replace as necessary a b d The two casing halves are matched and can only be replaced as a pair Replace all thrustwashers Bearing cones must be a push fit on trunnions Remove all nicks and burrs from differential mounting surface and crown wheel location face and spigot Crown wheels and pinions are supplied as matched pairs and must not be replaced separately see section on dismantling axle assemblies ASSEMBLY 9 Reverse the procedure for dismantling 1 to 7 taking care to align casing halves 10 Torque bolts in accordance with table AT3 tightening on opposite sides and not to be followed around the diameter for diff bolts and crown wheel bolts 11 Mount differential trunnions on vee blocks and check runout of crown wheel back face This must not exceed 0 05mm 0 002 If excessive check for dirt or damage 12 Bearing cones and shims to be fitted in accordance with instruction for setting backlash Section HUB ASSEMBLI
9. L DRIVE DRIVE DIFF BRG GEAR DIFF STRADDLE PINION GEAR CAP CARRIER CASE HSG BO NUT BOLT BOLT COVER BOLT SCREW 8HA 10HA 24mm 8 12mm 12mm 10mm 12mm 12 9 Grade 10 9 Grade 8 8 Grade 8 8 Grade 129 142 125 142 27 38 98 102 e For axles with collapsible spacers the nut is tightened until the torque to turn the pinion is in accordance with table AT2 eq Isnw SNU syog ZLY uim eouepJoooe ul SI uoiuid ay ay peuejufi si Inu ay s 90eds ejqisdej oo YING asay esneoeg WNOZE WNOE 93 6g L UNCOL 68 UNSE Zc 6 0L UNOZL OSI 8 8 uug 88 88 WWZL 88 0 x 8 8 WW 4001 61 91 8b cv 69 09 9 9 2 69 S L 8LL 5 i idi A 5 idi ONN ui x n 061 081 91 6 ONG 91 4 ONN 91 4 8 9 1 WNOZ LOST INN Y WNOE 9Z WNZY L 6Z L UNCOL 68 WN8E Ze 601 62 4 1 88 WWB 8 8 88 88 WWOL 8 8 Has WN86 98 WNC WNOE 9Z UNZOL 68 WN8G 19 WNOE 93 WN8S 1LS 621 LLZ 8 8 WWB 8 8 WWZL 88 88 WWOL uuo 8 8 HdAOO xx 1109 INN INN HdAOO uvao LlOg HdlHHVO HV3O NOINId QIOdAH AHV
10. NWIHd ASVO SAIC uvao 94g 3410 GIOdAH VOI 13H HQ SNOYOL J19VL GALINIT NOISSINSNVHI AHf8SITIVS Section J DIAGRAMS SECTION J DIAGRAMS J1 SECTION J DIAGRAMS
11. S D 1 DRUM BRAKES 1 Remove the brake drums 2 Remove the hub as outlined in section C1 or C2 as appropriate 3 Remove brake securing screws which may be of either the nut and bolt variety or tapped into the tube flange 4 Note the position of the adjuster actuator etc to identify correct handling of replacement brake assembly 5 Reassemble in reverse order as specified in the appropriate section Ensure that the brake drum path is clear and smooth Difficulty in fitting the brake drum may mean that the brake show adjuster is fully expanded SECTION 3 BRAKES D 2 DISC BRAKES 1 Break the locking wire securing the two caliper mounting bolts 2 Remove the caliper mounting bolts being careful not to lose the washers and shims 3 Remove the caliper assembly 4 Clean the disc faces 5 Present the replacement caliper assembly onto the mounting flange having ensured the correct handing 6 Insert shims between the caliper lug and the mounting flange on the tube to ensure that the Hydraulic pads are equidistant from the disc The securing bolts must be tightened to ensure correct seating of all the components To apply these first seat the small plain washer against the bolt head and then the large plain washer next to that T Tighten to 35 40 Ibt ft and reapply locking wire If hand brakes are fitted these are self adjusting and will be positioned correctly after initial application of the hand brake leve
12. age C 3 Section G GEAR TOOTH CONTACT TOOTH CONTACT CHART Diagrams show contact on drive gear tooth TOOTH CONTACT CONDITION REMEDY IDEAL TOOTH CONTACT 0 HEEL Evenly spread over profile Outer end nearer toe than heel 0 Inner end HEEL Outer end Coast TOE Drive Inner end HIGH TOOTH CONTACT Heavy on the top of the drive gear tooth profile Move the Drive PINION DEEPER into MESH i e Reduce the pinion cone setting HEEL Outer end TOE Inner end LOW TOOTH CONTACT Heavy in the root of the drive gear tooth profile Move the Drive PINION OUT of MESH i e Increase The pinion cone Setting HEEL Outer end Drive TOE Inner end TOE CONTACT Hard on the small end of the drive Gear tooth Move the Drive GEAR OUT of mesh i e INCREASE BACKLASH HEEL Outer end TOE Inner end HEEL CONTACT Hard on the large end of the drive gear tooth Move the Drive GEAR into MESH i e DECREASE BACKLASH BUT MAINTAIN MINIMUM BACKLASH Section H TABLES SALISBURY TRANSMISSION LIMITED TABLE 4HA 4HU 5HA 7HA 7DR 8HA 8DR 10HA 10HD 10DR NOMINAL 2 625 2 9685 2 219 3 125 3 500 PINION CONE DIFF 3 2660 3 4385 2 8920 3 8140 4 1273 BEARING SEAT Heavy DIAMETER 3 2674 3 4399 3 8934 3 8155 4 1256 3 8155 Light 3 8140 SALISBURY TRANSMISSION LIMITED
13. aring housing hub adjustment shims and axle shaft to be replaced Re assemble axle shaft taking care to carefully align splines in both differential side gear and brake plates Assemble bearing housing complete with bearing over axle shaft and locate on brake housing studs Fit bearing housing retaining nuts on the studs and finger tighten sufficient only to locate bearing housing Tap lightly end of shaft to ensure that no free play is apparent in opposing shaft assembly If necessary re tighten bearing housing retainer nuts sufficient only to lightly pinch bearing housing Using feeler gauges measure gap between bearing housing and brake housing faces Measurements to be taken at four equally spaced points around the bearing housing circumference Obtain the mean reading and add to this dimension 005 0 12mm This dimension thus found is the shim thickness required Remove bearing housing and re assemble using above shim pack between bearing housing and brake housing faces Assemble and tighten bearing housing nuts to correct torque figure Assemble hub componentry Check that end float exists on axle shaft assembly Re fit road wheels For replacing both axle shafts When removing bearing housing note shim thickness as fitted Re assemble one side of housing using a shim pack thickness the same as that removed Re assemble other side of axle using method as described in a above Section D BRAKES SECTION 3 BRAKE
14. can be moved slightly to and fro by turning the pinion in order to ensure maximum reading is obtained 36 Repeat operation on other differential bearing bore 37 Add the two readings and halve the result in order to obtain the mean figure If the pinion is set correctly a mean reading of zero should be obtained A negative reading indicates the pinion is set too high and shims need to be removed from under the inner pinion bearing cup A positive reading indicates that the pinion is set too low and more shims need to be added under the inner pinion bearing cup NOTES a The amount of variation away from zero gives the amount of shim adjustment required b If a change in shim pack is required it is essential that a new collapsible spacer is fitted when rebuilding Each spacer can be used once only 38 Assemble ring gear onto differential case and bolt together by gradually and evenly tightening the bolts Do not tighten one bolt at a time but work on diametrically opposite bolts This ensures the ring gear is seated correctly on the case It is advised to use Loctite studlock grade or similar locking compound on the bolt treads Do not use excessively and remove any surplus Tighten bolts to torque figures given in table AT3 39 Assemble differential bearing cones to differential case using press and suitable adaptor NOTE when pressing second bearing cone onto case seat first bearing cone into its cup in order to prevent damage to bearing
15. case etc 40 With bearing cups fitted onto cones lower differential case assembly into the carrier Take care when meshing gear and pinion not to damage teeth 41 Position a dial gauge as shown in figure AF6 42 Fit suitable shim packs between the differential bearing cups and carrier on each side in order to give a reading of 007 on the dial gauge when the gear backlash is measured lt is important that the pinion is not moved when measuring ring gear backlash otherwise false results are obtained The shim packs should be a resistance fit Shims are available in 003 005 010 and 030 NOTE When using new bearings rotate differential assembly approx six times whilst pressing towards each bearing in turn this is in order to settle bearings Following this adjust shim packs if necessary to give resistance fit and repeat backlash check 43 Remove differential assembly together with shim packs Carefully note to which end the shim pack relates add 003 shim to each pack in order to give bearing preload 44 Remove one differential bearing cone from case and fit appropriate shim pack to case trunnion Refit bearing cone 45 Repeat above on other differential bearing 46 Fit carrier stretcher tool to carrier and stretch carrier IMPORTANT DO NOT STRETCH CARRIER MORE THAN 010 012 MEASURED ACROSS STRETCHER HOLES 47 Assemble differential assembly together with bearing cups into carrier It may be necessary to tap lightly i
16. cates that the pinion is set too low and more shims need to be added under the inner pinion bearing cup NOTES a The amount of variation away from zero gives the amount of shim adjustment required b If a change in shim pack is required it is essential that a corresponding opposite change takes place under the outer pinion bearing cup i e if 003 is removed from the inner bearing cup shim pack to give the correct pinion height the 003 must be added to the outer bearing cup shim pack This is in order to maintain the correct preload for the two bearings as given in table AT2 38 39 40 41 42 43 44 45 46 47 Assemble ring gear onto differential case and bolt together by gradually and evenly tightening the bolts Do not tighten one bolt at a time but work on diametrically opposite bolts This ensures the ring gear is seated correctly on the case It is advised to use Loctite studlock grade or similar locking compound on the bolt treads Do not use excessively and remove any surplus Tighten bolts to torque figures given in table AT3 Assemble differential bearing cones to differential case using press and suitable adaptor NOTE when pressing second bearing cone onto case seat first bearing cone into its cup in order to prevent damage to bearing case etc With bearing cups fitted onto cones lower differential case assembly into the carrier Take care when meshing gear and pinion not to damage teeth Posi
17. e pressure does not result in movement of Hub alignment is incorrect Position outer bearing cone having applied a liberal quantity of lithium based grease Tighten inner Tube Nut until slight binding is felt when rotating Hub in both directions Back off nut a quarter of a turn Insert tab washer in place and tighten outer tube nut to a force of 100 120 Ibf ft Check end float which should be as follows 13 14 15 Drum Brake applications 003 008 Disc Brake applications 003 005 If end float is incorrect reposition inner tube nut as appropriate and repeat operations Using large screwdriver bend over locking tabs onto nearest convenient flat on both inner and outer tube nuts Clean off faces of both hubs and shaft and fit new gasket applying sealant to both faces Replace axle shaft and secure bolts using either lockwashers or fresh lockstraps as appropriate Tighten bolts to 38 43 Ibf ft SECTION C HUB ASSEMBLIES C 4 SERVICE INSTRUCTIONS FOR ADJUSTMENT OF AXLE SHAFT END FLOAT ON SEMI FLOATING SEALED BRAKED AXLES 05HA SERIES The recommended end float for the axle shaft of the above axle is 003 008 0 08 0 20mm As it is unlikely that servicing agents would have the necessary DTL gauges suitable for directly measuring this adjustment the following procedure is recommended For replacing single axle shaft Jack axle clear of ground and remove road wheels Remove hub assembly be
18. e the loop down the axle tube and over the broken end of the shaft for a sufficient distance so that on pulling the loop will bind on the shaft and withdraw it from the differential side gear This applies where sufficient shaft remains 1 minimum length 6 To remove a broken axle shaft with the break close to the spline it is necessary then to withdraw the opposite shaft and remove the differential assembly complete i e follow the instruction conveyed in Page A 1 A 2 or A 3 Examine shaft oil seal which is pressed inside the axle tube for wear misplaced garter spring etc and replace if necessary Examine the shaft bearing for where and replace if necessary If replacing axle shaft bearing ensure bearing cup is seated correctly in bearing housing if this is not done creeping will occur which will result in excessive shaft end float which in turn will damage the bearing Re assemble components in reverse ensuring that inner shaft oil seal is not damaged when shaft is re fitted If new bearing is fitted ensure correct axle shaft endfloat 003 009 is obtained by the removal addition of shims from one axle end only Refit hub in accordance with Page C 2 N B New paper gaskets must be fitted when components are re assembled Re grease the assembly by means of the grease nipple SECTION F AXLE SHAFTS F 3 FULLY FLOATING This procedure is covered within the strip and re build procedure for the fully floating hub in P
19. g in flange bolt holes Remove the locknut and washer 14 Remove companion flange from pinion using withdrawal tool by supporting pinion inside carrier and tapping flange with hide or other suitable hammer 15 Remove pinion complete with inner bearing cone 16 Remove oil seal gasket and oil thrower discard seal and gasket 17 Remove outer bearing cone 18 Remove inner and outer bearing cups from carrier Extraction slots are provided in the carrier for ease of removal purposes Carefully note the shim pack thickness under both cups Discard the shims because of possible damage during removal 19 Remove inner bearing cone from pinion using service tool CLEAN AND CAREFULLY CHECK ALL COMPONENTS FOR WEAR OR DAMAGE PRIOR TO REASSEMBLY REASSEMBLY 20 21 22 23 24 25 26 27 28 29 30 31 32 Check that pinion and gear are matched in that the serial no s on the end face of the pinion and on the outer diameter of the gears are identical lt should be noted that marks on the pinion end adjacent to serial number have no significance in service Assembly inner bearing cone onto pinion using service tool or suitable press Select new shim pack the size of that removed from the inner bearing Insert into carrier Press inner bearing cup into housing using press and suitable adaptor if new gear set or bearings are used the shim pack is to be chosen to give the correct pinion height setting as described late
20. inst stretcher or carrier but use packing 9 Ease off turn buckle and remove spreader 10 Remove ring gear from differential case assembly if necessary 11 Remove bearing cones from differential case trunnion diameter if necessary 12 Disassemble differential in accordance with appropriate sheet 13 Prevent rotation of companion flange by using service tool having pegs locating in flange bolt holes Remove the locknut and washer 14 Remove companion flange from pinion using withdrawal tool by supporting pinion inside carrier and tapping flange with hide or other suitable hammer 15 Remove pinion complete with inner bearing cone 16 Remove oil seal gasket and oil thrower discard seal and gasket 17 Remove outer bearing cone and collapsible spacer discard spacer 18 Remove inner and outer bearing cups from carrier Extraction slots are provided in the carrier for ease of removal purposes Carefully note the shim pack thickness under inner cup Discard the shims because of possible damage during removal 19 Remove inner bearing cone from pinion using service tool CLEAN AND CAREFULLY CHECK ALL COMPONENTS FOR WEAR OR DAMAGE PRIOR TO REASSEMBLY REASSEMBLY 20 Check that pinion and gear are matched in that the serial no s on the end face of the pinion and on the outer diameter of the gears are identical It should be noted that marks on the pinion end adjacent to serial number have no significance in service 21 As
21. ion head 29 Fit washer and new lock nut 30 Before tightening locknut apply a small amount of oil to both bearings 31 Tighten nut gradually rotating the pinion assembly slightly at intervals throughout until torque to turn companion flange stated in table AT2 is attained NOTE Take care to tighten nut gradually as torque loading on bearings is applied rapidly 32 Check the correct positional setting of the pinion is as follows a Check the nominal pinion cone setting distance from table AT1 b Check the variation figure marked on the head of the pinion see figure AF3 This figure is given in thousandths of an inch c Add these figures to give the actual required pinion cone setting distance Example Nominal cone distance 2 500 2 500 Marked variation 3 003 2 002 Actual required distance 2 503 2 498 d Read the differential bearing seat diameter from table AT1 e Subtract half the figure at 32 d from that at 32 c to give nominal clock setting height Example 32 c 2 503 32 d 1 500 Clock setting height 1 003 33 Using a small magnetic base clock and setting piece or slipblocks set the clock to the dimension obtained in 32 e this method of clock setting is shown in figure AF4 34 Ensure the pinion end is free from burrs 35 Mount the magnetic base of the clock onto the pinion end so that the stylus registers in the bottom of the differential bearing bore This is shown in figure AF5 The clock
22. n order to assemble Do not force assembly into position as this could cause damage to bearings 48 Fit bearing caps noting that markings match with markings on carrier 49 Tighten bearing cap bolts to torque figures as stated in table 50 Check companion torque to turn figures as stated in table AT2 51 Re fit carrier cover using new gasket Tighten cover bolts to figure given in table AT3 52 Re fit half shafts axle shafts 53 Re fill with oil of correct grade Section B DIFFERENTIAL ASSEMBLIES SECTION B DIFFERENTIAL UNITS B1 2 PIN DIFFERENTIAL DISMANTLING 1 Remove fixings and withdrawn crown wheel 2 Remove pinion mate shaft fixing pin 3 Withdraw pinion mate shaft 4 Hold one side gear and rotate the other until pinion mates can be withdrawn from differential case 5 Remove pinion mate thrustwashers Remove side gears and side gear thrustwashers Remove differential bearing cones using extractor and press INSPECTION 8 Examine all components and replace as necessary a Replace all thrustwashers b Bearing cones must be a push fit on the trunnion c Remove all nicks burrs etc from crown wheel location surfaces ASSEMBLY 9 Reverse the procedure for dismantling 1 to 6 10 Fitring gear as per section on dismantling and reassembly of axle centres 11 Bearing cones and shims to be fitted in accordance with instructions for setting backlash SECTION B DIFFERENTIAL UNITS B2 4 PIN D
23. nes and be aware of the damage compressed air can cause if misused Always make sure lifting equipment is in good condition and the Safe Working Load exceeds the weight of the component to be lifted Always use suitable supports e axle stands or baulks of timber in conjunction with hydraulic jacks etc Never rely on hydraulic jacks alone to support a machine Be aware of hot surface temperatures and take care when draining hot oils Always dispose of waste oils in accordance with local and national regulations Whenever possible always disconnect the battery or battery isolator when working on the machine to prevent electrical shorts and unauthorised starting Refer to the operators handbook for a guide to the correct sequence for assembling components and sub assemblies Oils fuels silicone sealer etc can cause skin diseases if allowed to contaminate the skin Always apply barrier creams wear suitable protective clothing or when contamination is unavoidable clean the area with soap and water as soon as possible Do not use thinners or other solvents to clean skin Health 8 Safety is a matter of common sense If common sense is applied correctly the risk of accidents can be reduced Spares for Salisbury Axles fitted to Winget Equipment can only be obtained from Winget Limited or one of our authorised distributors and not from GKN Salisbury Always quote your machine s serial number and model together with axle serial number and m
24. ng distance from table AT1 b Check the variation figure marked on the head of the pinion see figure AF3 This figure is given in thousandths of an inch c Add these figures to give the actual required pinion cone setting distance 33 34 35 36 37 Example Nominal cone distance 2 500 2 500 Marked variation 3 003 2 002 Actual required distance 2 503 2 498 d Read the differential bearing seat diameter from table AT1 e Subtract half the figure at 32 d from that at 32 c to give nominal clock setting height Example 32 c 2 503 32 d 1 500 Clock setting height 1 003 Using a small magnetic base clock and setting piece or slipblocks set the clock to the dimension obtained in 32 e this method of clock setting is shown in figure AF4 Ensure the pinion end is free from burrs Mount the magnetic base of the clock onto the pinion end so that the stylus registers in the bottom of the differential bearing bore This is shown in figure AF5 The clock can be moved slightly to and fro by turning the pinion in order to ensure maximum reading is obtained Repeat operation on other differential bearing bore Add the two readings and halve the result in order to obtain the mean figure If the pinion is set correctly a mean reading of zero should be obtained A negative reading indicates the pinion is set too high and shims need to be removed from under the inner pinion bearing cup A positive reading indi
25. odel when ordering spare parts 5HA series axles are designed to operate under arduous conditions and providing they are regularly and correctiy maintained they will provide long trouble free service The contents of this manual although correct at the time of publication may be subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused Winget Limited operate a policy of continuous product development Therefore some illustrations or text within this publication may differ from your machine INDEX INTRODUCTION A CENTRE SUB ASSEMBLIES A 1 Shim adjusted centre sub assemblies A 2 Oollapsible Spacer centre sub assemblies DIFFERENTIAL ASSEMBLIES B 1 2 Pin Diff Assembly B 2 4 Pin Diff Assembly HUB ASSEMBLIES C 1 Semi Floating Hub C 2 Semi Floating Outrigger Hub C 3 Fully Floating Hub C 4 End Float Adjustment on 05HA OIMPD Hub BRAKES D 1 Drum Brakes D 2 Disc Brakes D 3 Oil Immersed Brake 05HA INTENTIONALLY BLANK AXLE SHAFTS F 1 Semi Floating F 2 Semi Floating Outrigger F 3 Fully Floating G GEAR TOOTH CONTACT H TABLES J DIAGRAMS Section A CENTRE HUB ASSEMBLIES SECTION A 1 DISMANTLING AND REASSEMBLY OF SHIM ADJUSTED CENTRE amp SUB ASSEMBLIES This section covers certain 7HA 4
26. r SECTION D BRAKES D3 INSTRUCTIONS FOR REPLACING AND ADJUSTING BRAKES FOR STL 5HA OIL IMMERSED BRAKED AXLES S F TYPE DESIGN DIS ASSEMBLY If brake adjustment only is required the following axle strip down need not apply Adjustment instructions are given separately Remove axle shaft nut lock pin Remove axle shaft lock nut and washer Withdraw hub complete with Key Remove the nuts and washers holding the bearing housing in position Withdraw housing assembly from studs The bearing housing assembly incorporates the oil seal shaft bearing cup and bearing housing O ring Carefully remove the retaining bearing housing shims taking care not to damage them Withdraw axle shaft complete with axle shaft bearing cone Remove the nuts retaining brake housing plate Withdraw brake housing cover plate from studs Remove the brake friction discs and reaction plates which will now be loose within the brake housing Remove brake reaction pin Remove brake housing pressed cover and gasket Upon removal of this cover the conical return spring will be free and should be removed also From end opening of brake housing remove the circlip retaining the pin between the pull rod and the brake actuator Push pin through pull rod and swing pull rod away from actuator Remove actuator from housing Remove internal brake friction discs and reaction plates from brake housing Discard all worn plates Worn plates are iden
27. r Select new shim pack the size of that removed from the outer bearing Insert into carrier Press outer bearing cup into housing using press and suitable adaptor if new gear set or bearings are used the shim pack is to be chosen to give a bearing preload as stated in table AT2 NOTES a Ensure both cups are pressed and firmly seated into carrier b Take care not to damage face or taper of bearings whilst assembling c Both bearing cups may be assembled together if the appropriate service tool is available Insert pinion and pinion bearing into housing and support in position Fit outer bearing cone over pinion and seat into cup Fit oil slinger Fit new oil seal gasket and oil seal The seal is to be fitted with the lip facing inwards As an aid to assembly and to prevent lip damage apply a small amount of grease to lip prior to assembly The oil seal should be pressed into housing using a suitable adaptor locating near the outer diameter of the seal Fit companion flange If it is necessary to press or tap the flange into position do not let flange react against bearing but react against support on pinion head Fit washer and new lock nut Before tightening locknut apply a small amount of oil to both bearings Tighten nut gradually to figure given in table AT3 rotating the pinion assembly slightly at intervals throughout Check the correct positional setting of the pinion is as follows a Check the nominal pinion cone setti
28. semble bearing housing together with bearing cup and seal onto studs Fit lockwashers and nuts and tighten to recommended torque Fit leather wiping seal Fit hub assembly complete with bearing cup onto shaft Fit shaft key Fit shaft washer and nut and tighten to recommended torque Fit new nut locking pin On axles built prior to June 1979 Serial No prefix F79 bearing housing 05HA 014 012 and hub 05HA 928 113 were used in place of the above mentioned components It should be noted that the old level hub and bearing housings are not interchangeable as individual items with the new level components ADJUSTMENT either side of axle shaft from top cover Although 016 4mm is the theoretical clearance figure to use in practice it is found that a 015 shim is more readily available 3 When correct adjustment is achieved re assemble brake housing cover Tighten pull rod nut to lock brakes and thus take up all slack in the system 2 Loosen pull rod nut until a clearance of 0001 0 25mm per working brake surface is obtained With an eight plate assembly this would give 016 4mm total clearance This clearance should be measured by two shims of correct thickness being inserted between a suitable brake disc and brake reaction plate complete with conical return spring correctly located in position RECOMMENDED TORQUE TIGHTNESS Axle Shaft Nut 130 140 Ibf ft Bearing Housing Nuts 88 43 Ibf ft Brake Cover N
29. sembly inner bearing cone onto pinion using service tool or suitable press 22 Select new shim pack the size of that removed from the inner bearing Insert into carrier Press inner bearing cup into housing using press and suitable adaptor if new gear set or bearings are used the shim pack is to be chosen to give the correct pinion height setting as described later 23 Select new shim pack the size of that removed from the outer bearing Insert into carrier Press outer bearing cup into housing using press and suitable adaptor NOTES a Ensure both cups are pressed and firmly seated into carrier b Take care not to damage face or taper of bearings whilst assembling Both bearing cups may be assembled together if the appropriate service tool is available 24 Insert pinion and pinion bearing into housing and support in position 25 Fit new collapsible spacer over pinion shank slide outer bearing cone over pinion and seat onto collapsible spacer 26 Fit oil slinger 27 Fit new oil seal gasket and oil seal The seal is to be fitted with the lip facing inwards As an aid to assembly and to prevent lip damage apply a small amount of grease to lip prior to assembly The oil seal should be pressed into housing using a suitable adaptor locating near the outer diameter of the seal 28 Fit companion flange If it is necessary to press or tap the flange into position do not let flange react against bearing but react against support on pin
30. tified when the plate surface goes below both of the circular grooves This worn condition is evidenced by the noticeable increase in pedal effort for the same vehicle retardation ASSEMBLY GENERAL NOTE Replace all worn or damaged components and lightly grease bearings and oil seals prior to assembly 10 11 12 13 Insert correct number of internal brake friction discs and reaction plates into housing in correct sequence Loosly assemble actuator plate into housing Locate actuator plate arms in correct position with pull rod and insert locator pin complete with inner circlip from back of the brake housing Attach outer circlip to pin Use new circlip Assemble correct number of brake friction discs and reaction plates onto shaft spline in correct order Assemble shaft complete with bearing cone together with brakes plates and discs through actuator plate and inner friction discs and reaction plates taking care whilst engaging the shaft splines into both inner side gear and the brake discs Assemble brake reaction pin into brake housing ensuring that all brake reaction places are correctly aligned Assemble brake cover plate over studs ensuring correct location of brake reaction pin Fit cover plate locking nuts and tighten to correct torque Use a good quality gasket sealant beneath plate surface i e silicone gasket compound Fit correct shim amount i e that removed from the axle over bearing housing location studs As
31. tion a dial gauge as shown in figure AF6 Fit suitable shim packs between the differential bearing cups and carrier on each side in order to give a reading of 007 on the dial gauge when the gear backlash is measured It is important that the pinion is not moved when measuring ring gear backlash otherwise false results are obtained The shim packs should be a resistance fit Shims are available in 003 005 010 and 030 NOTE When using new bearings rotate differential assembly approx six times whilst pressing towards each bearing in turn this is in order to settle bearings Following this adjust shim packs if necessary to give resistance fit and repeat backlash check Remove differential assembly together with shim packs Carefully note to which end the shim pack relates add 003 shim to each pack in order to give bearing preload Remove one differential bearing cone from case and fit appropriate shim pack to case trunnion Refit bearing cone Repeat above on other differential bearing Fit carrier stretcher tool to carrier and stretch carrier IMPORTANT DO NOT STRETCH CARRIER MORE THAN 010 012 MEASURED ACROSS STRETCHER HOLES Assemble differential assembly together with bearing cups into carrier lt may be necessary to tap lightly in order to assemble Do not force assembly into position as this could cause damage to bearings Fit bearing caps noting that markings match with markings on carrier Tighten bearing cap
32. uts 65 75 Brake Pressing Cover 19 22 Ibf ft Pressing Bolts 175 190 Nm 51 58Nm 89 102 Nm 26 30 Nm Section E BLANK Section F AXLE SHAFTS SECTION F AXLE SHAFTS F 1 1 2 6a 10 10a 11 12 SEMI FLOATING Remove brake drum Remove hub in accordance with Page C1 Remove the brake back plate retaining bolts the outer oil seal assembly the hub bearing retainer plate and the brake back plate taking care not to lose or damage any of the shaft bearing adjusting shims which control the shaft endfloat Check outer oil seal for wear misplaced garter spring etc and replace is necessary Remove the axle shaft with its taper roller bearing To remove a broken axle shaft make a loop at one end of a length of stiff wire slide the loop down the axle tube and over the broken end of the shaft for a sufficient distance so that on pulling the loop will bind on the shaft and withdraw it from the differential side gear This applies where sufficient shaft remains i e minimum length 6 To remove a broken axle shaft with the break close to the spline it is necessary then to withdraw the opposite shaft and remove the differential assembly complete i e follow the instruction conveyed in Pages A 1 A 2 or A 3 Examine the shaft oil seal which is pressed inside the axle tube and if necessary withdraw same and replace with a new seal Examine the shaft bearing for wear and if replacement
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