pra 352 series - axletech...understand all instructions before performing any product service. some...

PRA 352 SeriesPlanetary Axles

ASM-0094E SERVICE MANUAL

March 2019

PRA 352 W2HPRA 352 G2HPRA 352 G2MPRA 353 G2HPRA 353 G2MPRA 383 G2HPROA 352 W2HPROA 382 W2H

Table of Contents

i

Table of ContentsService Notes ...................................................ii

Asbestos and Non-Asbestos Fibers Warning ......iii

Service Precautions .......................................... vTowing ............................................................. vRepair Warnings .............................................. viTorque Specifi cations ...................................... viCleaning ......................................................... viDamaged Components .................................... viRepair Welding ............................................... viiOmissions ...................................................... vii

General Assembly Instructions ....................... viiiTapered Roller Bearings ................................ viiiCastings ....................................................... viiiGears ............................................................ viiiSeals .............................................................. ixMounting Surfaces .......................................... ixFasteners ......................................................... xTapered Ball Joint Removal ............................... xDuo-Cone Oil Seal Assembly ........................... xi

Introduction .................................................... 1Description ......................................................1Identifi cation Tag .............................................1Model Nomenclature ........................................1Exploded Views ................................................2 PRA 352 - Trumpet Variation No. 1 ................2 PRA 352 - Trumpet Variation No. 2 ................4 PRA 353/383 ...............................................6 PROA 352/382 ............................................8 PROA 352/382 ......................................... 10

Removal & Disassembly ................................. 12Remove Axle.................................................. 12Disassemble Ball & Ramp Brake ................... 12Disassemble Trumpet Assembly .................... 13Disassemble Planetary System & Axle Shaft .. 14Disassemble Hydraulic Apply Wet Disc Brake . 15Disassemble Three Function Wet Disc Brake .. 15Disassemble Main Housing ........................... 17Disassemble Diff erential Case ....................... 18Disassemble Pinion Bearing Cage ................. 20

Preparing Parts for Assembly .......................... 22

Assembly & Installation ................................. 23Assemble Diff erential Case ........................... 23Check Rotating Resistance of Diff erential Gears (Not Limited Slip) ................................ 26Assemble Drive Pinion & Bearing Cage .......... 27Adjust Pinion Bearing Preload (Without Press) ........................................................... 28Adjust Thickness of Pinion Bearing Cage Shim Pack (Depth of Pinion) .......................... 30Install Pinion Bearing Cage Assembly on Main Housing ................................................ 31Install Diff erential Housing Assembly into Main Housing (with Shims) ............................ 33Install Diff erential Housing Assembly into Main Housing (With Adjusting Ring 2 Sides) ... 34Assemble Axle Shaft ...................................... 35Assemble Trumpet Assembly ......................... 36Assemble Hydraulic Apply Brake Housing Assembly ...................................................... 38Hydraulic Apply Brake Housing Functional Test ............................................................... 39Assemble Three Function Brake Housing Assembly ...................................................... 40Assemble Ball and Ramp Brakes, Brake Discs, Reaction Plate & Pins.......................... 42Assemble Three Function Brakes, Brake Discs, Reaction Plate & Pins.......................... 43Install Housing Assembly into Main Housing .. 43Assemble Three Function Brake Release Bolts & Sleeves ............................................. 44Assemble Ball and Ramp Brake Cylinder Assembly & Install on Main Housing .............. 44

Adjustment ................................................... 46Check Ring Gear Runout ................................ 46Adjust Pinion and Ring Gear .......................... 47Teeth Contact Patterns .................................. 48Verifi cation Procedure ................................... 48Correct Contact Patterns ............................... 49Incorrect Contact Patterns ............................ 50

Lubrication .................................................... 52Lubricant Replacement ................................. 52Lubricant Specifi cations ................................ 53

Appendix ....................................................... 54Torque Specifi cations .................................... 54Tools ............................................................. 62

Service Notes

ii

Service Notes

This service manual describes the service and repair procedures for the PRA 352 Series Axle. The information contained in this manual is current at the time of publica-tion and is subject to change without notice or liability.

Follow all company procedures when you service or repair equipment or components. Understand all instructions before performing any product service. Some procedures require the use of special tools for safe and correct ser-vice. Failure to use special tools when required can cause serious personal injury to service personnel, as well as, damage to equipment and components.

The instructions contained in this service manual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair, and replacement of the AxleTech product described herein.

! DANGERInstallation, maintenance, and replacement of such prod-ucts requires a high degree of skill and experience. The consequences of improper installation, maintenance, or replacement (including the use of inferior or substandard components) are grave and can result in product failure and resulting loss of control of the vehicle, possible injury or death of persons, and/or possible future or additional product damage.

AxleTech does not authorize anyone, other than highly skilled and experienced individuals, to attempt to utilize the instructions contained in this manual for the installa-tion, maintenance, or replacement of the product de-scribed herein, and AxleTech shall have no liability of any kind for damages arising out of (or in connection with) any other use of the information contained in this manual.

UpdatesFor the latest version of this manual, please visit the AxleTech web site at www.axletech.com. AxleTech Customer Service can be reached at 800-540-2794 or via email at [email protected].

NotationsAxleTech International uses the following notation to warn the user of possible safety problems and to provide information that will prevent damage to equipment and components:

! DANGERA DANGER indicates a procedure that you must follow exactly or it will cause death or serious injury.

! WARNINGA WARNING indicates a procedure that you must follow exactly or it may cause death or serious injury.

! CAUTIONA CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components.

NOTEA NOTE indicates an operation, procedure, or instruction that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier.

Asbestos and Non-Asbestos Fibers Warning

iii


OSHA* Toxic and Hazardous Substances 29 CFR 1910.1001

Work practices and engineering controls for automotive brake and clutch inspection, disassembly, repair and assembly -- Mandatory

This mandatory appendix specifi es engineering controls and work practices that must be implemented by the employer during automotive brake and clutch inspection, disassembly, repair, and assembly operations.

Proper use of these engineering controls and work practices by trained employees will reduce employees’ asbestos exposure below the permissible exposure level during clutch and brake inspection, disassembly, repair, and assembly operations. The employer shall institute engineering controls and work practices using either the method set forth in paragraph [A] or paragraph [B] of this appendix, or any other method which the employer can demonstrate to be equivalent in terms of reducing employ-ee exposure to asbestos as defi ned and which meets the requirements described in paragraph [C] of this appendix, for those facilities in which no more than 5 pairs of brakes or 5 clutches are inspected, disassembled, reassembled and/or repaired per week, the method set forth in para-graph [D] of this appendix may be used:

[A] Negative Pressure Enclosure/HEPA Vacuum System Method

(1) The brake and clutch inspection, disassembly, repair, and assembly operations shall be enclosed to cover and contain the clutch or brake assembly and to prevent the release of asbestos fi bers into the worker’s breathing zone.

(2) The enclosure shall be sealed tightly and thoroughly in-spected for leaks before work begins on brake and clutch inspection, disassembly, repair, and assembly.

(3) The enclosure shall be such that the worker can clearly see the operation and shall provide impermeable sleeves through which the worker can handle the brake and clutch inspection, disassembly, repair and assembly. The integri-ty of the sleeves and ports shall be examined before work begins.

(4) A HEPA-fi ltered vacuum shall be employed to maintain the enclosure under negative pressure throughout the op-eration. Compressed-air may be used to remove asbestos fi bers or particles from the enclosure.

(5) The HEPA vacuum shall be used fi rst to loosen the as-bestos containing residue from the brake and clutch parts and then to evacuate the loosened asbestos containing material from the enclosure and capture the material in the vacuum fi lter.

(6) The vacuum’s fi lter, when full, shall be fi rst wetted with a fi ne mist of water, then removed and placed immedi-ately in an impermeable container, labeled according to paragraph (j)(5) of this section and disposed of according to paragraph (k) of this section.

(7) Any spills or releases of asbestos containing waste material from inside of the enclosure or vacuum hose or vacuum fi lter shall be immediately cleaned up and dis-posed of according to paragraph (k) of this section.

[B] Low Pressure/Wet Cleaning Method

(1) A catch basin shall be placed under the brake assem-bly, positioned to avoid splashes and spills.

(2) The reservoir shall contain water containing an organic solvent or wetting agent. The fl ow of liquid shall be con-trolled such that the brake assembly is gently fl ooded to prevent the asbestos-containing brake dust from becom-ing airborne.

(3) The aqueous solution shall be allowed to fl ow between the brake drum and brake support before the drum is removed.

(4) After removing the brake drum, the wheel hub and back of the brake assembly shall be thoroughly wetted to suppress dust.


iv

(5) The brake support plate, brake shoes and brake com-ponents used to attach the brake shoes shall be thor-oughly washed before removing the old shoes.

(6) In systems using fi lters, the fi lters, when full, shall be fi rst wetted with a fi ne mist of water, then removed and placed immediately in an impermeable container, labeled according to paragraph (j)(4) of this section and disposed of according to paragraph (k) of this section.

(7) Any spills of asbestos-containing aqueous solution or any asbestos-containing waste material shall be cleaned up immediately and disposed of according to paragraph (k) of this section.

(8) The use of dry brushing during low pressure/wet clean-ing operations is prohibited.

[C] Equivalent Methods

An equivalent method is one which has suffi cient written detail so that it can be reproduced and has been demon-strated that the exposures resulting from the equivalent method are equal to or less than the exposures which would result from the use of the method described in paragraph [A] of CFR 1910.1001. For purposes of making this comparison, the employer shall assume that expo-sures resulting from the use of the method described in paragraph [A] of this appendix shall not exceed 0.016 f/cc, as measured by the OSHA reference method and as averaged over at least 18 personal samples.

[D] Wet Method

(1) A spray bottle, hose nozzle, or other implement capa-ble of delivering a fi ne mist of water or amended water or other delivery system capable of delivering water at low pressure, shall be used to fi rst thoroughly wet the brake and clutch parts. Brake and clutch components shall then be wiped clean with a cloth. Any wastewater generated must be captured and properly disposed of without allow-ing it to dry on any surfaces.

(2) The cloth shall be placed in an impermeable container, labeled according to paragraph (j)(4) of the standard and then properly disposed of as an asbestos waste, or the cloth shall be laundered in a way to prevent the release of asbestos fi bers in excess of 0.1 fi ber per cubic centimeter of air.

(3) Any spills of solvent or any asbestos containing waste material shall be cleaned up immediately according to paragraph (k) of this section.

(4) The use of dry brushing during the wet method opera-tions is prohibited.

[59 FR 40964, Aug. 10, 1994; 60 FR 33972, June 29, 1995; 77 FR 17778, March 26, 2012]

For more information, visit www.osha.gov, or call OSHA at 1-800-321-OSHA(6742), TTY 1-877-889-5627.

*References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers em-ployed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.

Service Precautions

v

Service Precautions

! DANGER• ALWAYS WEAR PROPER EYE PROTECTION AND

OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT TO PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE SERVICE.

• WORK IN A WELL-VENTILATED AREA.

• NEVER USE GASOLINE, OR SOLVENTS CONTAINING GASOLINE. GASOLINE CAN EXPLODE.

• DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND OR POLISHED PARTS. DOING SO WILL CAUSE DAMAGE TO THE PARTS.

• USE HOT SOLUTION TANKS OR ALKALINE SOLUTIONS CORRECTLY. READ THE MANUFACTURER’S INSTRUCTIONS BEFORE USING HOT SOLUTION TANKS AND ALKALINE SOLUTIONS. THEN CAREFULLY FOLLOW THE INSTRUCTIONS.

• SOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS, AND CAUSE BURNS. EXAMPLES OF SOLVENT CLEANERS ARE CARBON TETRACHLORIDE, EMULSION-TYPE, AND PETROLEUM-BASED CLEANERS. READ THE MANUFACTURER’S INSTRUCTIONS BEFORE USING A SOLVENT CLEANER, THEN CAREFULLY FOLLOW THE INSTRUCTIONS. ALSO FOLLOW THE PROCEDURES BELOW.

• PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE VEHICLE FROM MOVING. NEVER WORK UNDER A RAISED VEHICLE SUPPORTED BY ONLY A FLOOR JACK. ALWAYS SUPPORT A RAISED VEHICLE WITH SAFETY STANDS. CHOCK THE WHEELS AND MAKE SURE THE UNIT WILL NOT ROLL BEFORE RELEASING BRAKES. A JACK CAN SLIP OR FALL OVER. SERIOUS PERSONAL INJURY CAN RESULT.

• IMPROPER JACKING AND SUPPORT METHODS CAN CAUSE STRUCTURAL DAMAGE THAT RESULTS IN LOSS OF VEHICLE CONTROL, SEVERE PERSONAL INJURY OR DEATH. REFER TO THE VEHICLE MANUFACTURER FOR PROPER JACKING AND SUPPORT METHODS.

! WARNINGFOLLOW THE SPECIFIED PROCEDURES IN THE INDICAT-ED ORDER TO AVOID PERSONAL INJURY OR EQUIPMENT MALFUNCTION/DAMAGE.

BEFORE STARTING A VEHICLE:

• Sit in the driver’s seat

• Place shift lever in neutral

• Set the parking brake

BEFORE WORKING ON A VEHICLE OR LEAVING THE CAB WITH ENGINE RUNNING:



• Chock the wheels

WHEN PARKING THE VEHICLE OR LEAVING THE CAB:



! CAUTION• DO NOT RELEASE THE PARKING BRAKE OR

ATTEMPT TO SELECT A GEAR UNTIL THE AIR PRESSURE IS AT THE CORRECT LEVEL.

• TO AVOID DAMAGE TO THE TRANSMISSION DURING TOWING:


• Lift the drive wheels off of the ground or disconnect the driveline

• DO NOT OPERATE VEHICLE IF ALTERNATOR LAMP IS LIT OR IF GAUGES INDICATE LOW VOLTAGE.

TowingDue to the wide range of environments and applications for AxleTech axles, it is recommended to follow the towing instructions from the vehicle Original Equipment Manufac-turer (OEM).

Service Precautions

vi

Repair Warnings

! DANGERUSE OF OTHER THAN RECOMMENDED TOOLS, PARTS, AND INSTRUCTIONS LISTED IN THIS PUBLICATION MAY PLACE THE SAFETY OF THE SERVICE TECHNICIAN OR VEHICLE DRIVER IN JEOPARDY.

DO NOT WELD REPAIR, HEAT, BEND, OR RECONDITION AXLE COMPONENTS. THIS WILL REDUCE COMPONENT STRENGTH, VOID AXLETECH’S WARRANTY, AND CAN RESULT IN SERIOUS PERSONAL INJURY AND DAMAGE TO COMPONENTS. ALWAYS REPLACE DAMAGED OR OUT-OF-SPECIFICATION COMPONENTS.

• When disassembling various assemblies, lay all parts on a clean bench in the same sequence as removed to simplify assembly and reduce the possibility of losing parts.

• Provide a clean work area. Make sure no dirt or foreign material enter the unit during repair and assembly.

• Disconnect the vehicle’s battery before removing or installing electronic parts.

• The location of components varies with each OEM.

• The removal and installation procedure described for each component may vary between vehicles.

• Use a rubber mallet for disassembly and assembly procedures. NEVER hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

• Remove nicks, marks, and burrs from parts having machined or ground surfaces. Use a fi ne fi le, India stone, emery cloth or crocus cloth for this purpose.

Torque Specifi cations• Tightening torque specifi cations indicated in this

manual must be adhered to at all times.

• A tightening torque weaker than indicated may lead to a shearing stress and may break the bolt.

• A stronger tightening torque may lead to yielding of the bolt or an increasing risk of cracking.

Cleaning• Remove gasket material using a gasket scraper taking

care not to damage machined surfaces.

• Steam clean or pressure wash the assembly after plugging all breathers, vents, and hydraulic inlets.

NOTE: NEVER direct full pressure at any of the seals (input shaft, wheel hubs, or brakes).

• Use solvent cleaners or alkaline solutions to clean all metal parts with rough surfaces. Parts must remain in hot solution tanks until completely cleaned and heated. Rinse alkaline solution off with water after cleaning.

• Use solvent cleaners and a brush to clean all metal parts that have ground or polished surfaces.

NOTE: NEVER clean ground or polished surfaces with water, steam, alkaline solution, or place in a hot tank.

• Dry all parts after washing using clean rags or paper towels.

• Apply a light oil fi lm to all parts to be reused and reassembled.

• If parts are being stored after cleaning, apply a corrosion-preventive material to all machined surfaces. Store the parts in a special paper or other material that prevents corrosion.

Damaged Components• All damaged components must be replaced by new

components.

• Clean and repair the threads of fasteners and holes. Use a die or tap of the correct size or a fi ne fi le for this purpose.

• Replace any fastener if corners of the head are worn.

• Since the cost of a new part is generally a small fraction of the total cost of downtime and labor, avoid reusing a questionable part that could lead to additional repairs and expense.

• Always use genuine AxleTech replacement parts.

Service Precautions

vii

Repair WeldingIn the interest of safety and preserving the service life of drive axle assemblies, AxleTech recommends that assem-blies are not repair welded. Repair welding can detract from the structural integrity of a component, particularly to heat treated parts where the benefi t of heat treatment may be nullifi ed by welding.

Since it can be extremely hazardous and detrimental to repair weld components of any kind, repair welding can be approved only where stringent controls are imposed and equipment, customarily located at manufacturing facilities, is employed, so as to minimize the potentially detrimental eff ects of repair welding.

OmissionsEvery eff ort has been made to ensure the accuracy of all information in this manual. However, AxleTech makes no expressed or implied warranty or representation based on the enclosed information. Any errors or omissions may be reported to AxleTech, 1400 Rochester Road, Troy, Michi-gan, 48083 USA.

General Assembly Instructions

viii

General Assembly InstructionsTapered Roller Bearings

! CAUTIONDRY BEARINGS WITH CLEAN PAPER OR RAGS. NEVER USE COMPRESSED AIR, WHICH CAN CAUSE ABRASIVE PARTICLES TO CONTAMINATE THE BEARINGS. DAM-AGE TO COMPONENTS AND REDUCED LINING LIFE CAN RESULT.

If parts are clean and properly lubricated, it is rare for bearings to be damaged. Proper installation is also criti-cal to avoid vibration, noise, and reduced bearing life.

Bearings should be replaced when:

• Bearing surfaces show abnormal wear

• Bearings are chipped (due to improper cleaning during assembly, improper lubrication, or a broken component inside the case)

• Centers of the large diameter end of the rollers are worn level with or below the surface

• Centers of the large diameter end of the rollers are worn to a sharp edge

• A roller groove is worn in the cup or cone inner race surfaces visible at the small or large diameter ends of both parts

• Deep cracks or breaks are present in the cup, cone inner race, or roller surfaces

• Bright wear marks are present on the outer surface of the roller cage

• Etching and pitting is present on the rollers and on surfaces of the cup and cone inner race that touches the rollers

• Spalling or fl aking is present on the cup and cone inner race surfaces that touch the rollers

During disassembly:

• Remove bearings with pullers designed for this purpose to avoid damaging the bearing.

• Carefully wash and re-lubricate all bearings as removed and protectively wrap until ready for use.

• Store all bearings in a dry and clean area to minimize the possibility of corrosion, contamination, or other damage.

During assembly:

• Install bearings in a clean environment, free from dust, debris, moisture, and other contaminants.

• Machining, fi ling, soldering, grinding, etc. should be kept away from the assembly area to prevent contaminating the bearings.

• Check the cleanliness of the bearing:• If the bearing is new, unpack it immediately

before assembly.• Used bearings should be cleaned with petrol or

benzine and then oiled.

• Verify the bore is deburred and cleaned before installing the bearing. Use 180-grit emery cloth to remove small imperfections in the metal.

• Bearings are installed the easiest by cooling or heating (in hot oil to 80°C) instead of using a press. Do not apply any shock or impact techniques (like hammering) to install the bearings.

• When a bearing has been heated for assembly, apply a small amount of grease or oil after assembly.

• When installing on a tight shaft, force is to be applied to the inner ring only.

Castings• Inspect for damage or cracking. Replace as required.

NEVER weld to repair the casting.

Gears• Inspect for pitting or damage. Replace as required.

• Replace beveled gear set, as required, with a matched set.


ix

Seals

! WARNINGWHEN APPLYING SOME SILICONE GASKET MATERIALS, SMALL AMOUNTS OF ACID VAPOR ARE PRESENT. TO PREVENT POSSIBLE SERIOUS INJURY, THE WORK AREA MUST BE WELL-VENTILATED. IF THE SILICONE GASKET MATERIAL GETS INTO YOUR EYES, FLUSH THEM WITH WATER FOR 15 MINUTES. HAVE YOUR EYES CHECKED BY A DOCTOR AS SOON AS POSSIBLE.

Recommended Lubricant: GRADE NLGI 2

• O-rings: After removal, always replace with new ones.

• Lipped seals: All disassembled seals shall be discarded and replaced by a new seal.

• Gaskets: After disassembly, always install a new paper or silicone gasket.

• Silicone Gaskets - Apply a 0.125” (3.18 mm) diameter continuous bead of silicone gasket material around one surface. Also apply the gasket material around the edge of all the fastener holes on that surface. Assemble immediately and wait 20 minutes before fi lling the assembly with lubricant.

0.125" (3.18 MM)DIAMETERSILICONE GASKETMATERIAL BEAD

! CAUTIONTOO MUCH GASKET MATERIAL CAN BLOCK LUBRI-CATION PASSAGES. DAMAGE TO COMPONENTS CAN RESULT.

During assembly:

• Verify the seal bearing surface edges are free of burrs and nicks that may damage seals.

• Lubricate properly:• Lubricate the entire interior surface of the ring

and primarily the seal lips.• Pack the space between the lips with grease.

NOTE: Do not use an excessive quantity of lubricant since liquefaction may occur during operation and appear outside the housing. This could easily be mistaken for a leak.

• The ring shall be engaged in its housing perpendicularly and concentrically to the shaft.

• Do not damage the seal lips and turn them over during installation.

Mounting SurfacesFor all mounting surfaces that do not use an o-ring seal, use Loctite 5699 RTV Silicone Gasket.

Product characteristics:

• Color: Grey

• Adhesive power: Weak, nevertheless, do not use on centering; only on the faces.

• Temperature Resistance: -67 to 392°F (-55 to 200°C)

• TO BE USED WITH CARE: Avoid any contact with eyes and skin.

During disassembly:

• In the event of sticking, tap the parts to break the Loctite fi lm.

• Remove particles of Loctite as thoroughly as possible.

• Clean and carefully degrease surfaces (any lubricant prevents setup therefore making the product ineff ective) using a solvent or by washing the parts.

• Let all components dry completely.

During assembly:

• Apply a single bead to one of the mating surfaces well around the attachment holes.

• Assemble the parts and tighten to the required torque.

• Leave to dry: Parts can be handled after 30 minutes.

• Total setup time: 18 to 24 hours


x

FastenersWhen installing fasteners without pre-applied adhesive, Loctite 243 Blue Threadlocker must be used unless other-wise stated.

Product characteristics:

• Color: Pale blue

• Temperature Resistance: -67 to 302°F (- 55 to 150°C)

• TO BE USED WITH CARE: Avoid any contact with eyes and skin.

During disassembly:

• If the removal of a capscrew becomes diffi cult due to a worn head or unusually high breakaway torque, the locking strength can be reduced by heating the threaded area to approximately 300°F (150°C). Heat slowly to avoid thermal stresses on the diff erential case and gears.

• Clean excess material off all surfaces as thoroughly as possible.

• Clean and carefully degrease surfaces (any lubricant prevents setup therefore making the product ineff ective) using a solvent or by washing the parts.

• Let all components dry completely.

• Replace any fastener if corners of the head are worn.

• Replace washers if damaged.

• Clean and repair threads of fasteners and holes. Use a die or tap of the correct size or a fi ne fi le for this purpose.

! CAUTIONTHREADS MUST BE WITHOUT DAMAGE AND CLEAN SO THAT ACCURATE ADJUSTMENT AND CORRECT TORQUE VALUES CAN BE APPLIED TO FASTENERS AND PARTS.

During assembly:

• Apply one drop to the threads, preferably at the end of the screw, of Loctite 243 Blue Threadlocker.

• Assemble the parts and tighten to the required torque.

• All screws shall be tightened within 5 minutes following assembly of the parts. The unit can be used 10 minutes after assembling.

NOTE: To reduce setup time, spray Loctite 7649 Locquic Primer N activator on the threads, allow to evaporate, and then apply Loctite 243.

Tapered Ball Joint RemovalCarriage ball joints use a tapered attachment fi t to their mating component. Often, it is not practical to procure a special tool to split the taper and separate the com-ponents. AxleTech Service recommends that ball joint tapered joints housed within steel or ductile iron com-ponents can be split using a “shock method”. The shock method involves impacting the component, with a steel hammer, close to the tapered location. (DO NOT directly impact the ball joint or stud directly.) This action tends to “shock” the tapered joint loose and is a common practice by AxleTech Service.

xi

Duo-Cone Oil Seal Assembly• Always follow correct procedures when mounting

and installing the Duo-Cone oil seals. Many Duo-Cone oil seal leaks result from errors made during mounting or installation of the oil seal components.

• Never let oil touch the toric ring or lodging ramps before both oil seal rings are installed in their mounting position.

! WARNINGTO AVOID SERIOUS PERSONAL INJURY, TRICHLORO-ETHYLENE MUST NOT COME IN CONTACT WITH YOUR SKIN. DO NOT SMOKE AND AVOID BREATHING VAPORS IN CLOSED ROOMS WITHOUT VENTILATION. DO NOT USE TRICHLOROETHYLENE NEAR FLAMES, WELDING OPERATIONS OR HOT SURFACES EXCEEDING 900°F (482°C).

1. Remove any dust, oil, or foreign material from the Toric ring (2), lodging ramps (4, 7), ring retention lips (3, 8), oil seal ring (1) and ring bore (5). Clean components with trichloroethylene and a clean cotton cloth or a paper towel.

1 – OIL SEAL RING2 – “TORIC” RING3 – BORE RETENTION LIP4 – BORE RAMP5 – RING BORE

1 2

3

4

5

6 – RING FACE7 – BORE RAMP8 – RING RETENTION LIP9 – INSTALLATION TOOL

6

7

9

8

! CAUTIONMAKE SURE THE TORIC RING (2) IS SEATED IN THE OIL SEAL RING (1). BE CAREFUL WORKING WITH THE TORIC RING AS CUTS AND SCRATCHES MAY CAUSE LEAKS.

1

2

2. Place the Toric ring (2) in the oil seal ring (1) in button of ring ramps (7) and against ring retention lip (8).

17

8

2

NOTE: Do not use any liquid that leaves a fi lm of oil or does not evaporate quickly.

3. Place the installation tool (9) under the oil seal ring with the Toric ring (2). Submerge the ring in a receptacle fi lled with trichloroethylene until the entire surface of the Toric ring is wet.

1

9

2

xii

4. With the Toric ring surface wet (2), use the installation tool (9) to install the oil seal ring and the Toric ring perpendicular to the ring bore. Use a rapid and uniform pressure to push the Toric ring under the ring retention lip.

1

9

2

5. Verify the mounting distance (A) in at least four places spaced 90° apart. The diff erence in the mounting distance (A) around the ring cannot be more than 0.04” (1 mm).

(A) 0.04 in (1 mm)

6. If adjustments are necessary, use the installation tool (9) to push the ring. Do not use your hands.

1

9

7. The Toric ring may become distorted if it is not entirely wet or if there is a sharp edge on the retention lip and bore.

! CAUTION• Misalignment or a twisted Toric ring may cause leakage in the Duo-Cone oil seal. If installation was not correct, remove the oil seal from the bore and repeat Steps 3-6.

• A Toric ring must never slide on any ramp of the oil seal ring or bore. To prevent sliding, wait at least two minutes for trichloroethylene to evaporate before con-tinuing with installation. When in the correct position, the Toric ring must roll only on ramps.

• A small piece of lint can separate the oil seal surfac-es and cause leaks.

8. Clean the oil seal surfaces with a lint-free cloth or paper.

9. Apply a thin, uniform fi lm of clean oil on the oil seal surfaces with cloth or a clean fi nger. Do not get oil on the Toric ring.

xiii

10. Make sure both bores are correctly aligned and concentric. Move slowly and carefully.

1

! CAUTIONDO NOT FORCE RINGS ABRUPTLY AGAINST EACH OTHER. A STRONG IMPACT MAY BREAK THE OIL SEAL COMPONENTS. WHEN THE SEAL IS INSTALLED PROPER-LY, FASTEN ALL COMPONENTS WELL.

If Duo-Cone oil seal is installed incorrectly, these condi-tions can result:

• Toric ring can warp.

1

2

5

• Warped ring can cause irregular pressure on ring surface resulting in oscillating movements of oil seal.

• Diff erent pressures on oil seal surfaces can cause seepage, wear and leaks.

• Oscillating oil seals allow dirt to enter.

The fi gure below shows an incorrect installation of an oil seal in its mounting position. The upper bore is stopped and the lower lodge is rotating.

B

X

A

Y

CL

XThe fi gure below shows the same lower bore after rotation of 180 degrees. In this position, high pressure occurs on points “A” and “Y”. This high pressure variation may dam-age rings. Points “B” and “X” will develop low pressure and possible leakage.

B

X

A

Y

CL X

Introduction

1

Introduction

DescriptionThe AxleTech PRA 352 Series Planetary Axle is a dou-ble-reduction single-speed unit that has:

• A hypoid or spiral pinion and ring gear set

• Bevel gears in the diff erential assembly with 2 or 4 diff erential pinion gears

• A diff erential case assembly mounted on two tapered roller bearings

• A planetary system with 3 or 4 planetary pinion gears

• A trunnion mounting option

• An oil bath disc brake system in three diff erent designs:

• Ball and Ramp

• Hydraulic Apply Wet Disc

• Three Function Brake

Model Nomenclature

P R O A 3 5 2 G 2 M

P - PLANETARY R - RIGID IF APPLICABLE:

O - OSCILLATING OR PINMOUNTING

HOUSING TYPE DESIGNATION:

A - POT OR SPLIT CARRIER

WET DISC BRAKE DESIGNATION:

W2H - 3 FUNCTION/HYDRAULIC APPLY

G2H - HYDRAULIC BALL AND RAMP

G2M - MECHANICAL BALL AND RAMP

NOTE: ALL BRAKES ARE 9 INCHDIAMETER (229 mm)

DIFFERENTIAL:

2 - SPIRAL

3 - HYPOID

WHEEL END NUMBER OFPLANETARY GEARS:

35 - 3 PLANETARY GEARS

38 - 4 PLANETARY GEARS

Identifi cation Tag

MODEL

CUST No.

SERIAL No.

RATIO DATE

All products are identifi ed by the model and serial num-ber. This information is stamped on the identifi cation tag and affi xed to the case. Have reference numbers handy when ordering replacement parts or requesting service repairs.

DO NOT REMOVE OR DESTROY THE IDENTIFICATION TAG.

Introduction

2

Exploded Views

PRA 352 - Trumpet Variation No. 1

47

Introduction

3

Item Description Item Description

1 Central Housing 43 Outer Piston2 Level Plug 44 Piston O-ring3 Drain Plug 45 Piston O-ring4 Vent Plug 46 Piston Brake Shim5 Hydraulic Line Bleeder 47 Inner Piston6 Cover 48 Piston O-ring7 Capscrew 49 Spring8 Diff erential Case Assembly 50 Washer9 Washer 51 Bolt-Return Spring10 Capscrew 52 Spring11 Spacer 53 Brake Actuating Plate12 Thrust Washer 54 Capscrew13 Side Gear 55 Friction Disc14 Thrust Washer 56 Stationary Disc15 Pinion Gear 57 Brake Reaction Plate16 Spider 58 Brake Disc Lock Pin17 Spiral Gear & Pinion 59 Sun Gear18 Washer 60 Ring Gear19 Capscrew 61 Capscrew20 Bearing Cone 62 Planetary Pinion Spider21 Bearing Cup 63 Planetary Pinion Shaft22 Brake Housing 64 Capscrew23 Capscrew 65 Housing24 Adjuster Ring 66 Bearing Cone25 Adjuster Ring Lock 67 Bearing Cone26 Capscrew 68 Bearing Cup27 Pinion Cage Shim 69 Bearing Cup28 Pinion Cage Assembly 70 Output Axle Shaft29 Bearing Cup 71 Wheel Bolt30 Bearing Cup 72 Axle Shaft Oil Seal31 Bearing Cone 73 Adjusting Nut32 Bearing Cone 74 Adjustin Nut Lock Capscrew33 Drive Pinion Shim 75 Thrust Washer34 Washer 76 Kit Roller35 Capscrew 77 Roller Spacer36 Pinion Nut 78 Planetary Pinion37 Driven Sleeve 79 Washer38 Drive Sleeve 80 Snap Ring39 Snap Ring 81 Stud40 Motor Adapter Flange 82 Capscrew41 Washer 83 Washer42 Capscrew 84 Nut

Introduction

4


11 10

12

2

9 8 4

37

34

210

11

65

73

64 63

62

6

1314

151

6766

69

68717071

69

32

3130

38

39

6059 58

6159

5756

55 4849

46

5052

5154 44

43A

33 34

41

38

39

4543

4240

38 3941

2120

1926

1617

182423

2225

2728

40

4245

44 4750 49

4654

53 5251

48

55

56

73

72

38

57

59

59

60

6263

6465

3736

39 3433 30

31 32

2961A

58A

4753

Introduction

5


1 Center Housing 39 Friction Disc

2 Diff erential Case Assembly 40 Brake Reaction Plate

3 Side Gear 41 Brake Disc Lock Pin

4 Side Gear Thrust Washer 42 Ring Gear

5 Pinion Gear 43 Sun Gear, Short

6 Pinion Gear Thrust Washer 43A Sun Gear, Long

7 Spider Diff erential 44 Adjusting Nut

8 Spiral Gear Capscrew Plain Washer 45 Adjusting Nut Lock Capscrew

9 Spiral Gear Capscrew 46 Planetary Pinion Flange

10 Bearing Cone 47 Shaft Planetary Pinion

11 Bearing Cup 48 Planetary Pinion Axle Capscrew

12 Spiral Gear & Pinion Assembly 49 Planetary Pinion Thrust Washer

13 Diff erential Case Plain Washer 50 Planetary Pinion

14 Diff erential Case Capscrew 51 Rollers

15 Diff erential Case Shim 52 Spacer Rollers

16 Pinion Cage 53 Planetary Pinion Plain Washer

17 Bearing Cup 54 Snap Ring

18 Bearing Cone 55 Bearing Cone

19 Pinion Bearing Spacer 56 Bearing Cup

20 Bearing Cup 57 Housing

21 Bearing Cone 58 Center Housing Stud

22 Universal Joint Yoke 58A Center Housing Stud

23 Oil Slinger 59 Washer

24 Oil Seal 60 Center Housing Stud Nut

25 Pinion Nut 61 Center Housing Capscrew

26 Pinion Cage Shim 61A Center Housing Capscrew

27 Pinion Cage Washer 62 Bearing Cup

28 Pinion Cage Capscrew 63 Bearing Cone

29 Brake Housing 64 Axle Shaft OIl Seal

30 Brake Piston 65 Axle Shaft

31 Piston Oil Seal 66 Center Housing Cover

32 Piston Oil Seal 67 Center Housing Cover Capscrew

33 Piston Return Spring 68 Drain Plug

34 Return Spring Bolt 69 Level Plug

35 Adjuster Ring 70 Vent Plug

36 Adjuster Ring Lock 71 Hydraulic Bleeder

37 Adjuster Ring Capscrew 72 Capscrew

38 Stationary Disc 73 Wheel Bolt

Introduction

6

PRA 353/38368

6765

666462

828180

8381606361697370

71727574 77

78 7959

5737

39

474544

49

43 4241

3738

36

36 858486

37

5840

878889

2013

14

1918

4

872

911

11

12

12

31

787958

77767074737271

75

26151617

27

28

2322

21

3029

3

65 10

33 32

34 59

82

806081

24

25 35

38

434241

3637

393757

4049

4445474856

515253

50

89 5446

55

3637

68

67

666462

83816361

65

69

535251

5089 54

5648

4655

Introduction

7


1 Center Housing 46 O-ring2 Diff erential Case 47 O-ring3 Side Gear 48 Brake Cylinder4 Thrust Washer 49 Capscrew5 Pinion Gear 50 Adjusting Nut6 Thrust Washer 51 Nut7 Diff erential Pinion Shaft 52 Brake Cylinder Cover8 Pinion Shaft Lock Pin 53 Capscrew9 Washer 54 Washer10 Capscrew 55 Capscrew11 Bearing Cone 56 Capscrew12 Bearing Cup 57 Reaction Brake Plate13 Spiral Gear and Pinion 58 Ring Gear14 Diff erential Case Shim 59 Sun Gear15 Pinion Cage 60 Housing16 Bearing Cup 61 Bearing Cone17 Bearing Cone 62 Bearing Cup18 Drive Pinion Shim 63 Bearing Cup19 Bearing Cup 64 Bearing Cone20 Bearing Cone 65 Axle Shaft21 Motor Adapter Flange 66 Axle Shaft Oil Seal22 Driven Sleeve 67 Wheel Bolt23 Drive Sleeve 68 Wheel Nut24 Snap Ring 69 Planetary Pinion Spider25 Pinion Nut 70 Planetary Pinion Shaft26 Pinion Cage Shim 71 Capscrew27 Washer 72 Thrust Washer28 Capscrew 73 Planetary Pinion29 Washer 74 Spacer30 Capscrew 75 Kit Rollers31 Brake Housing 76 Washer32 Capscrew 77 Snap Ring33 Adjuster Ring 78 Adjusting Nut34 Adjuster Ring Lock 79 Adjusting Nut Lock Capscrew35 Capscrew 80 Stud (M14)36 Stationary Disc 81 Washer37 Friction Disc 82 Nut38 Brake Disc Lock Pin 83 Capscrew39 Brake Assembly 84 Cover40 Pin 85 Capscrew41 Snap Ring 86 Level Plug42 Brake Control Rod 87 Drain Plug43 Brake Cylinder Support 88 Vent Plug44 Spring 89 Hydraulic Line Bleeder45 Brake Piston

Introduction

8

PROA 352/382(With Mechanical Drive Option)

17

199

97

95

96

65

104

1211 8

9

7

29

30

33

40 393837

34 35

36

28

58

85 77

84

86

57

53

32

21

2322

151413

4319

1820

46

24 26 27

16

49

50

5251

9399

41

42

94

4

2 3

31

98

4767

72

68

69

64

89

9291

90

100

48

73

6566

60

616263

8382

565554

7680

7978

4344

45

59

64A

8788

70

71

8174

Introduction

9

Item Description Item Description1 Main Housing 52 Spring

2 Bushing 53 Return Spring Capscrew

3 Trunnion Oil Seal 54 Return Spring

4 Diff erential Case Assembly 55 Inner Piston

5 Diff erential Case Capscrew 56 Shim Pack

6 Diff erential Case Washer 57 Small Oil Seal

7 Side Gear 58 Outer Piston

8 Friction Discs Shim Pack 59 Oil Seal

9 Friction Drive Disc 60 Reaction Plate

10 Friction Driven Discs 61 Ring Gear

11 Compression Discs 62 Short Sun Gear

12 Thrust Washer 63 Long Sun Gear

13 Pinion Gear 64 Axle Shaft Housing

14 Pinion Gear Thrust Washer 64A Bushing

15 Spider 65 Bearing Cone

16 Gear Capscrew Washer 66 Bearing Cup

17 Gear Capscrew 67 Bearing Cup

18 Diff erential Case Cone Bearing 68 Bearing Cone

19 Diff erential Case Cup Bearing 69 Axle Shaft

20 Gear and Pinion Assembly 70 Wheel Flange

21 Pinion Bearing Case 71 Flange Capscrew

22 Shaft Side Cone Bearing 72 Axle Shaft Oil Seal

23 Shaft Side Cup Bearing 73 Wheel Capscrew

24 Pinion Bearing Spacer 74 Weheel Nut

25 --Not Shown-- 75 --Not Shown--

26 Head Side Cup Bearing 76 Planetary Gear Pin

27 Head Side Cone Bearing 77 Pin Capscrew

28 Adapter Flange 78 Flange Side Thrust Washer

29 Universal Joint Yoke 79 Planetary Gear

30 Defl ector 80 Rollers Spacer

31 Pinion Oil Seal 81 Rollers Kit

32 Driven Sleeve 82 Thrust Washer

33 Drive Sleeve 83 Snap Ring

34 Snap Ring 84 Adjusting Nut

35 Pinion Nut 85 Adjusting Nut Lock Capscrew

36 Pinion Bearing Cage Shim 86 Planetary Spider

37 Bearing Cage Capscrew Washer 87 Short Stud

38 Bearing Cage Capscrew 88 Long Stud

39 Flange Capscrew Washer 89 Washer

40 Flange Capscrew 90 Nut

41 Brake Housing 91 Bolt

42 Brake Housing Capscrew 92 Brake Release Bolt

43 Adjusting Ring 93 Main Housing Cap

44 Adjusting Ring Lock 94 Cap Capscrew

45 Lock Capscrew 95 Level Plug

46 Stationary Disc 96 Drain Plug

47 Friction Disc 97 Grease Plug

48 Brake Disc Lock Pin 98 Vent Plug

49 Action Plate 99 Bleeder

50 Bolt 100 Spacer

51 Medium Oil Seal

Introduction

10

PROA 352/382

Introduction

11


1 Center Housing 49 Brake Piston Assembly

2 Bushing 50 Piston O-ring

3 Trunnion Oil Seal 51 Piston O-ring

4 Lubrication Fitting 52 Brake Piston Shim

5 Level Plug 53 Brake Piston

6 Drain Plug 54 Piston O-ring

7 Vent Plug 55 Spring

8 Hydraulic Line Bleeder 56 Washer

9 Cover 57 Bolt-Return Spring

10 Capscrew (M8 x 1.25 x 16.0) 58 Spring

11 Diff erential Case Assembly 59 Brake Actuating Plate

12 Washer 60 Capscrew

13 Capscrew (M10 x 1.5 x 80.0) 61 Stationary Disc

14 Drive Disc 62 Friction Disc

15 Driven Friction Disc 63 Brake Reaction Plate

16 Clutch Disc Shim 64 Brake Disc Lock Pin

17 Compression Disc 65 Sun Gear

18 Thrust Washer 66 Ring Gear

19 Side Gear 67 Capscrew

20 Thrust Washer 68 Planetary Pinion Spider

21 Pinion Gear 69 Planetary Pinion Shaft

22 Spider 70 Capscrew

23 Spiral Gear & Pinion 71 Housing

24 Washer 71A Bushing

25 Capscrew 72 Bearing Cone

26 Bearing Cone 73 Bearing Cone

27 Bearing Cup 74 Bearing Cup

28 Brake Housing 75 Bearing Cup

29 Capscrew 76 Output Axle Shaft

30 Adjuster Ring 77 Wheel Flange

31 Adjuster Ring Lock 78 Wheel Bolt

32 Capscrew 79 Capscrew

33 Pinion Cage Shim 80 Axle Shaft Oil Seal

34 Pinion Cage 81 Adjusting Nut

35 Bearing Cup 82 Adjusting Nut Lock Capscrew

36 Bearing Cup 83 Thrust Washer

37 Bearing Cone 84 Kit Rollers

38 Bearing Cone 85 Spacer

39 Drive Pinion Shim 86 Planetary Pinion

40 Washer 87 Washer

41 Capscrew 88 Snap Ring

42 Pinion Nut 89 Stud

43 Driven Sleeve 90 Capscrew

44 Drive Sleeve 91 Washer

45 Snap Ring 92 Nut

46 Motor Adapter Flange 93 Spacer

47 Washer 94 Brake Release Capscrew

48 Capscrew

Removal & Disassembly

12


Remove Axle! DANGER

TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR SAFE EYE PROTECTION WHEN PERFORMING VEHICLE MAIN-TENANCE OR SERVICE.

SUPPORT VEHICLE WITH SAFETY STANDS. DO NOT WORK UNDER A VEHICLE ONLY SUPPORTED BY JACK STANDS. JACK STANDS CAN SLIP OR FALL OVER AND CAUSE SERIOUS PERSONAL INJURY.

NOTE: While the housing confi guration of the axle being serviced may diff er from the illustrations shown, service instructions remain the same for all axle models ad-dressed in this manual.

1. Ensure the vehicle is on a level surface.

2. Place blocks under the wheels not being serviced to keep the vehicle from moving.

3. Raise the vehicle so the wheels being serviced are off the ground. Support the vehicle with safety stands.

4. Remove the axle from the vehicle.

5. Plug fl uid lines that were connected to the axle.

6. Place the axle in an appropriate repair stand. Center the main housing on the stand.

The PROA 352 axle is shown to illustrateprocedures in this maintenance manual

7. Remove the drain plugs from the brake housing and main housing with 12 mm Allen wrench. Drain the oil.

Disassemble Ball & Ramp BrakeNOTE:

• Identify all parts before disassembly to ensure proper reassembly.

• To disassemble the hydraulic apply wet disc brake, go to page 15.

• To disassemble the three function brake, go to page 15.

CAP

LOCK NUT

O-RING

WITHOUTHYDRAULICPRESSURE

BRAKECYLINDER

ADJUSTINGNUT

SPRINGPISTONO-RING

BRAKECYLINDERSUPPORT

1. Remove the brake cylinder cover.

2. Remove the nut and lock nut.

3. Loosen the brake cylinder capscrews.

4. Remove the brake cylinder assembly from the main housing.

! CAUTIONLOOSEN AND REMOVE THE BRAKE CYLINDER CAP-SCREWS ALTERNATELY TO AVOID SPRING LOAD DAM-AGE TO PARTS.

5. Disassemble the brake cylinder assembly. Remove the brake release capscrew. Loosen and remove the brake cylinder capscrews alternately to avoid spring load supported by only one capscrew.

6. Remove the spring, piston, and o-ring seals. Do not cut or scratch them.

7. Clean the cylinder and brake support surfaces. Do not damage ground surfaces.

8. Put parts for each brake cylinder assembly in separate plastic bags to avoid mixing them.


13

Disassemble Trumpet Assembly! DANGER

TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO COMPONENTS, BE VERY CAREFUL WHEN USING LIFTING DEVICES DURING REMOVAL AND DIS-ASSEMBLY PROCEDURES.

• INSPECT TO MAKE SURE NEITHER LIFTING STRAP IS DAMAGED.

• DO NOT SUBJECT LIFTING STRAPS TO ANY SHOCK OR DROP LOADING.

1. Support the trumpet to be serviced with a lifting device.

2. Loosen and remove the trumpet nuts and bolts.

NOTE: For three function brake design: If the bleeder and brake piston pressure ports are open, the trumpet assem-blies and ring gear will come off the center section easily without using puller holes. Cover pressure ports with rags to avoid contact with escaping oil.

3. Use two puller holes in trumpet fl ange to remove trumpet assembly from main housing.

4. Use Steps 1 to 3 to remove the second trumpet assembly.

5. Remove the ring gears from both sides through the two threaded puller holes. (Thread: M14 x 1.5 x 6 g)

! WARNINGDO NOT STRIKE STEEL PARTS WITH A STEEL HAMMER DURING REMOVAL AND DISASSEMBLY PROCEDURES. PARTS CAN BREAK AND CAUSE SERIOUS PERSONAL INJURY.

6. Remove from the main housing, the sun axle shaft, spacers (if used), compression plates, stationary discs, friction discs, lock pins, and expansive plate assemblies. For easier lock pin removal, strike the main housing with a brass hammer.


14

Disassemble Planetary System & Axle ShaftNOTE: Before removing planetary gears, place the housing in a horizontal position or place cloth between the pinion gear fl ange and the housing fl ange to keep rollers from falling down into the housing. To avoid mixing them, be sure to put rollers and spacers of each planetary gear in separate plastic bags.

1. Remove the snap rings using pliers. Disassemble the planetary gears and rollers.

2. Remove the axle shaft adjusting nut lock.

3. Remove the axle shaft adjusting nut lock with the special tool shown on page 62.

4. Remove the pinion gear fl ange. Lift it through the planetary gear pins.

5. Remove the axle shaft assembly and cone bearing. If necessary, use a press.

6. If it is necessary to change the bearing cups, remove them using the correct puller.

7. If it is necessary to replace the Duo-Cone oil seal or axle shaft roller bearing cone, use the correct puller.

DUO-CONEOIL SEAL


15

Disassemble Hydraulic Apply Wet Disc Brake1. Remove the piston return spring capscrews.

2. Remove the return springs.

3. Remove the brake piston assembly.

! CAUTIONGROUND OIL SEAL SURFACES MUST BE PROPERLY PROTECTED TO AVOID DAMAGE. WHENEVER NECES-SARY, USE NO. 600 SANDPAPER TO CORRECT ANY DAMAGE.

4. If necessary, replace the brake piston oil seals.

BRAKEHOUSING

BRAKEPISTON OIL

SEAL

RETURNSPRING

SPRINGCAPSCREW

5. Follow Steps 1 to 4 to disassemble the second brake piston.

Disassemble Three Function Wet Disc BrakeNOTE: Do not disassemble brake piston unless necessary.

1. Remove the return spring capscrews with a 4 mm Allen wrench. Remove the return springs and washers.

2. Remove the brake piston assembly from the brake housing as shown in the illustration below or place the brake housing on a bench with the opening turned down. Inject 80 psi (5.5 bar) compressed air through the service brake inlet to eject the brake piston.

3. Remove the shims.


16

! DANGER• USE A SPECIAL TOOL OR PRESS TO COMPRESS THE BRAKE ASSEMBLY TO AVOID SERIOUS PERSONAL INJU-RY FROM THE SPRING PRESSURE.

• OBSERVE ALL WARNINGS AND CAUTIONS PROVIDED BY THE PRESS MANUFACTURER CONCERNING PRESS OPERATION TO AVOID SERIOUS PERSONAL INJURY AND DAMAGE TO COMPONENTS.

4. Compress the brake piston assembly or place the assembly in a press and apply 1,000 lbs. (450 kg) of pressure.

PRESS

5. Remove the action plate capscrews.

NOTE: Before removing the action plate and other parts, mark the original assembly positions of all brake piston assembly parts. This procedure will make reassembly easier.

6. Remove the action plate and springs.

7. Remove the internal piston by placing the brake piston assembly on a bench with the action plate support surface turned down. Then tap the internal piston with a rubber mallet.

8. Use sand paper on the piston surfaces to remove any nicks or scratches.


17

Disassemble Main Housing1. Remove the adjusting nut capscrew lock.

2. Remove the adjusting nut capscrew and adjusting nut.

3. Remove the brake housing capscrews set deep in the brake housing fl ange. Use a long 6mm Allen wrench.

4. Remove the brake housing from the main housing. Strike the brake housing with a brass hammer or use two slots to remove it from the main housing. Be careful not to strike the ring gear.

5. Depending upon the ring gear position, remove the pinion bearing cage capscrews.

6. Remove the pinion bearing cage assembly from the main housing.

7. Remove the drive sleeve and snap ring.

DRIVE SLEEVE & SNAP RING

8. Remove the diff erential case assembly.

9. Remove the main housing cover.


18

Disassemble Diff erential Case1. Before disassembling the diff erential case, mark the

position of both halves and spider cross for easier reassembly.

2. Remove the diff erential case capscrews.

3. Separate the diff erential case halves. If necessary, use a brass or rubber hammer to separate the halves.

4. Remove the spider cross, diff erential pinions, side gears, and washers. If the diff erential case is a limited slip, remove the friction disc pack.

5. If the diff erential case is integral, remove the diff erential pinion axle lock capscrew and diff erential pinion axle. Then rotate the side gears and remove the diff erential pinions, side gears, and washers.


19

6. If necessary, separate the ring gear from the diff erential case. Remove the capscrews and washers fastening the ring gear.

7. Using a brass hammer, tap the ring gear to separate it from the diff erential case.

! WARNINGOBSERVE ALL WARNINGS AND CAUTIONS PROVIDED BY THE PRESS MANUFACTURER CONCERNING PRESS OPERATION TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO COMPONENTS DURING REMOV-AL AND DISASSEMBLY PROCEDURES.

8. If the diff erential case has two halves, remove the ring gear with a press after the capscrews have been removed. Use appropriate metal or wood supports.

SUPPORTS

9. If necessary, remove the cone bearings from the diff erential case. Use an appropriate puller or press.


20

Disassemble Pinion Bearing Cage1. If the pinion bearing cage was not removed, hold the

yoke, fl ange, or splined sleeve with an appropriate holder to remove the pinion nut.

If the pinion bearing cage was already removed, place it on the main housing and fasten with two capscrews.

! CAUTIONDO NOT USE A HAMMER OR MALLET TO LOOSEN OR REMOVE YOKE, FLANGE OR SPLINED SLEEVE. THE HAMMER OR MALLET CAN DAMAGE THE PARTS OR CAUSE ALIGNMENT PROBLEMS. DO NOT DAMAGE THE OIL SEAL SURFACE AREA.

2. Remove the yoke, fl ange, or splined sleeve from the drive pinion using the appropriate puller tool.

! CAUTIONTO AVOID OIL LEAKS, BE CAREFUL NOT TO DAMAGE THE MOUNTING SURFACE OF THE BEARING CAGE.

3. Remove the pinion oil seal. Pry at several points around the circumference between the seal, fl ange, and bearing cage.

OIL SEAL

4. Remove the capscrews and washers fastening the pinion bearing cage on the main housing.


21

! CAUTIONDO NOT USE A PRY BAR TO REMOVE THE BEARING CAGE FROM THE CARRIER. A PRY BAR CAN DAMAGE THE BEARING CAGE, SHIMS, AND MAIN HOUSING.

5. Remove the pinion bearing cage and shims from the main housing. If the bearing cage is tight within the main housing, strike the bearing cage at several points around the fl ange area with a leather, plastic, or rubber mallet.

6. If the shims are in good condition, keep them together for use later when the main housing is reassembled.

7. Before damaged shims are discarded, measure and record the total thickness of the pack. The dimension will be needed to calculate the drive pinion depth in the main housing when the gear set is installed.

8. Place the drive pinion and bearing cage in a press with the pinion shaft toward the top assembly. Support the bearing cage under the fl ange area with metal or wood blocks. Press the drive pinion through the bearing cage.

NOTE: The inner bearing cone and bearing spacer will remain on the pinion shaft.

9. If the pinion bearing needs to be replaced, remove the inner and outer bearing cups from the inside of the cage. Use a press and sleeve, bearing puller, or small drift and hammer.

10. If the pinion bearing need to be replaced, remove the inner bearing cone from the drive pinion using a press or bearing puller. The puller must fi t under the inner face of the cone to remove it without damage.

NOTE: If the bearing cup is changed, the bearing cone must also be replaced. The cup and cone must come from the same manufacturer.

Preparing Parts for Assembly

22

Preparing Parts for AssemblySee AMT-0445E - Parts Failure Analysis Service Manual for photos of various wear and check all parts for wear.

Replacement of damaged or worn parts will prevent breakdown of assembly later. Pay particular attention to inspecting:

• Tapered Roller Bearings - If any of the following conditions exist, the bearing must be replaced:

• The center of the large diameter end of the rollers are worn level with, or below, the surface.

• The center of the large diameter end of the rollers are worn to a sharp edge.

• A visible roller groove in the cup or cone inner race surfaces. The groove can be seen at the small or large diameter end of both parts.

• Deep cracks or breaks in the cup, cone inner race, or roller surfaces.

• Bright wear marks on the outer surface of the roller cage.

• Damage on rollers and on surfaces of the cup and cone inner race touching the rollers.

• Hypoid Pinion & Ring Gear Sets

• Hypoid drive pinions and ring gears are machined in matched sets. When a drive pinion or ring gear of a hypoid set needs to be replaced, both drive gear and pinion must be replaced at the same time.

• Inspect hypoid pinions and gears for wear and damage. Worn or damaged gears must be replaced. Also verify the cone bearing seats and spline in the pinion shaft.

• Main Diff erential Assembly - Inspect the following parts for wear or stress:

• Inside surfaces of both case halves

• Four trunnion ends of spider cross

• Teeth and splines of both side gears

• Teeth and bore of all diff erential pinions

• Friction disc packs, if used

• Both surfaces of all thrust washers

NOTE: Always replace old or worn thrust washers, diff erential side gears, and pinion gears in sets to avoid higher stress and early damage to parts.

• Axle Shafts - For wear and cracks at fl ange, shaft, and splines. Replace axle shaft, if required.

• Main Housing - For fractures and burrs in machined areas.

• Yoke - For wear at seal journal area. Replace yoke, fl ange, or sleeve if either shows too much wear at seal journal area.

• Planetary System - For existence of cracks, pitting, breaks, or sharp edges on planetary gear teeth, planetary gear axles, and rollers.

• Brakes - For condition of friction discs, brake piston springs, and internal brake housing surfaces.

Assembly & Installation

23


Assemble Diff erential Case! WARNING

• ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIP-MENT TO PREVENT PERSONAL INJURY WHEN PER-FORMING VEHICLE SERVICE.

• WHEN APPLYING SOME SEALANT MATERIALS, SMALL AMOUNTS OF ACID VAPOR ARE PRESENT. TO PREVENT POSSIBLE SERIOUS INJURY, THE WORK AREA MUST BE WELL-VENTILATED. IF THE SILICONE GASKET MATERIAL GETS INTO YOUR EYES, FLUSH THEM WITH WATER FOR 15 MINUTES. HAVE YOUR EYES CHECKED BY A DOCTOR AS SOON AS POSSIBLE.

1. Apply specifi ed lubricant on all parts of diff erential case assembly before installation.

! CAUTIONNEVER ATTEMPT TO PRESS A COLD RING GEAR ON THE FLANGED HALF OF THE DIFFERENTIAL CASE. A COLD RING GEAR WILL DAMAGE THE CASE BECAUSE OF THE TIGHT FIT. THE TIGHT FIT CAN CAUSE MISALIGN-MENT OR EXCESSIVE RUNOUT AND WILL MAKE FINAL BACKLASH AND TEETH CONTACT ADJUSTMENTS VERY DIFFICULT.

! WARNINGWEAR SAFE CLOTHING AND GLOVES TO AVOID SERIOUS PERSONAL INJURY WHEN TOUCHING THE HOT RING GEAR.

2. Expand the ring gear bore by heating the ring gear in a tank of water between 160°F to 180°F (71°C to 82°C) for 10 to 15 minutes. DO NOT USE AN OPEN FLAME SUCH AS A TORCH FOR THIS PROCEDURE.

3. Install the ring gear on the case half or in the integral diff erential case.

4. Apply Loctite 271 High-Strength Threadlocker to the ring gear fasteners and torque to 66-75 lbs. ft. (90-100 N·m).

5. Assemble the new cone bearings in both halves of the diff erential case or in both sides, if it is an integral diff erential case.

6. Install the side gear in the fl anged case half.

PRESS

NOTE: For the limited slip diff erential, go to Step 12.


24

7. Install the spider cross, diff erential pinions, and washers in the original assembly position.

SPIDER

a. If it is an integral diff erential case, install the side gears and washers in each original assembly side.

b. Install the diff erential pinions in the correct position by turning the side gears until the pinion holes are aligned with the diff erential pinion axle holes.

c. Install the diff erential pinion washers.

d. Install the diff erential pinion axle and lock capscrew. Fasten the capscrew to 17-23 lbs. ft. (23-31 N·m).

8. Install the other side gear over the spider and diff erential pinions.

9. Place the plain half of the diff erential over the fl anged half. Rotate the plain half as needed to align the match marks.

MARKS

10. Apply Loctite 271 High-Strength Threadlocker to the capscrews. Install the four capscrews into the case halves equally spaced and tighten to 48-64 lbs. ft. (64-87 N·m).


25

11. Install the other capscrews into case halves. Tighten the capscrews to 48-64 lbs. ft. (64-87 N·m).

12. Assemble the limited slip diff erential case.

a. Follow Steps 1 to 5.

b. Place the fl anged case half on a bench.

c. Begin stacking the disc pack with a drive disc followed by the driven friction discs. Ensure the lubrication grooves are aligned.

LUBRICATION GROOVES

Maintain the following sequence:

1) Drive disc

2) Driven friction disc

3) Drive disc


5) Drive disc


7) Drive disc

8) Shims (Do not stack until measurements are complete.)

9) Compression disc

10) Thrust washer (on side gear side)

d. Place the disc pack stack in a vise.

e. Use a micrometer to determine “D”, the height (thickness) of limited slip disc stack (includes thrust washer and compression disc). Take four readings, one at each of four points. Then average the readings to determine “D”.

TOP PLAIN HALFSIDE GEAR

PLAIN HALFSIDE GEARLIMITED

SLIP PACK

PLAIN HALFDIFF GEAR

PLAIN HALF SIDEGEAR MOVED TODETERMINE “A”

D

A

BC

SPIDER

DIFF CASEFACE (DATUM)

A: Differential case half flange to back of differential side gear distance

B: Differential case face to side gear seatC: Differential case half depthD: Stack height (thickness)

f. Use a depth gauge to determine “C”, the depth of diff erential case half. Take four readings. Average the readings for result.


26

TOP PLAIN HALFSIDE GEAR

PLAIN HALFSIDE GEARLIMITED

SLIP PACK

PLAIN HALFDIFF GEAR

PLAIN HALF SIDEGEAR MOVED TODETERMINE “A”

C

A

B

D

SPIDER

DIFFERENTIALCASE FACE (DATUM)

g. Place the removed plain half side gear on top as shown in the illustration above. Use a depth gauge to determine “A”, the distance from the diff erential case half fl ange to the backside of the diff erential side gear. Take four readings. Then average the readings for result.

h. Determine the clearance dimension: B - A = (C - D) - AThe clearance dimension must be greater than 0.05 mm and less than 0.15 mm.

i. Use the proper shim thickness to achieve the clearance specifi ed in Step H.

j. Assemble the friction discs in the diff erential case using the sequence outlined in Step C including the shims. Ensure the discs are lubricated.

k. Drop the side gear spline through the disc pack.

l. Repeat Steps A to J for the plain diff erential case half.

m. Follow Steps 9 to 11 to assemble the diff erential case.

Check Rotating Resistance of Diff erential Gears (Not Limited Slip)NOTE: Make a tool to check the rotating resistance of the diff erential gears, 50 lbs. ft. (68 N·m). The tool can be made from a sun gear matching the spline of the diff eren-tial side gear.

APPROXIMATELY12 INCHES (304.6 mm)

1. Place the diff erential case assembly in a vise with soft metal covers on the vise jaws. Install the tool into the diff erential until the splines of tool and one side gear are engaged.


27

2. Attach a torque wrench to the tool nut and rotate the diff erential gears. As the diff erential rotates, read the torque value indicated on the dial.

3. If the torque value exceeds the specifi cation of 50 lbs. ft. (68 N·m), disassemble the gears from the diff erential case.

4. Check the diff erential case halves, spider, gears, and thrust washers for problems causing excessive torque values. Repair or replace parts.

5. After parts are repaired or replaced, assemble the parts and repeat Steps 1 to 4.

Assemble Drive Pinion & Bearing Cage! WARNING

OBSERVE ALL WARNINGS AND CAUTIONS PROVIDED BY THE PRESS MANUFACTURER CONCERNING PRESS OPERATION TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO COMPONENTS DURING ASSEM-BLY AND INSTALLATION PROCEDURES.

1. Place the bearing cage in a press.

SLEEVE

BEARING CUP

2. Support the bearing cage with metal or wood blocks.

3. Press the bearing cup into the bearing cage bore until the cup is fl at against the bottom of the bore. Use the correct size sleeve to install the bearing cup.

NOTE: Use same procedure for both bearing cups.

4. Place the drive pinion in a press. The gear head (teeth) must face toward the bottom.

5. Press the inner bearing cone on the drive pinion shaft until the cone is fl at against the gear head. Use a sleeve of the correct size against bearing inner race.

SLEEVE


28

6. Apply axle lubricant on the bearing cups in cage and bearing cones.

7. Install the drive pinion into the bearing cage.

8. Install the bearing spacer(s) in the pinion shaft against the inner bearing cone.

NOTE: Spacers control the preload adjustment of the drive pinion bearings.

OUTERCONEBEARING

BEARINGSPACER

DRIVE PINION INNERBEARINGCONE

BEARING CAGE

9. Install the outer bearing cone on the pinion shaft against the spacer.

NOTE: Do not install the pinion oil seal in the bearing cage before the bearing preload adjustment. Continue adjusting preload of pinion bearings.

10. Press outer cone bearing with 10 ton force and check the bearing preload.

Adjust Pinion Bearing Preload (Without Press)NOTE:

• If the preload value is below the specifi ed range, install a thinner bearing spacer.

• If the preload value is over the specifi ed range, install a thicker bearing spacer.

Calculation Example

Data:

Radius: 9.3 cm (3.65 in)

Load: 2.3 Kg (5.0 lbs)

Calculation Procedure:

2.3 Kg x 9.3 cm = 21.4 Kg-cm

5.0 lbs. x 3.65 in = 18.25 lbs. in.

Conversion to N·m:

21.4 x 0.098 = 2.1 N·m

18.25 x 0.113 = 2.1 N·m

• To convert lbs. in. to N·m: multiply by 0.113

• Kg-cm to N·m: multiply by 0.098

1. Lubricate the bearing cups and cones with the specifi ed oil.

2. Install the yoke or fl ange without the pinion oil seal.

3. Install the pinion bearing cage assembly on the main housing without the bearing cage shims.

4. Fasten the bearing cage assembly on the main housing with two capscrews. Apply the minimum torque of 67 lbs. ft. (90 N·m).


29

5. Use the appropriate tool to fasten the pinion through the yoke, fl ange, or splined sleeve.

6. Tighten the pinion nut to a minimum torque value of 465 lbs. ft. (630 N·m).

7. Rotate the pinion bearing cage several times so the bearings make normal contact.

8. Attach the torque wrench on the drive pinion nut. Rotate the pinion and check if preload is in the specifi ed range. Make the reading during the rotation, not the starting value.

9. If the pinion bearing preload torque value is under or above the specifi ed preload torque of 5-20 lbs. in. (0.55-2.2 N·m), change the shims to thicker or thinner size, as necessary. Repeat the pinion bearing preload check.

10. After getting specifi ed preload, remove bearing cage from main housing and disassemble yoke or input fl ange.

! CAUTIONMAKE SURE THE OIL SEAL LIPS ARE CLEAN AND FREE FROM DIRT. DIRT CAN CAUSE LEAKAGE BETWEEN THE SEAL AND YOKE OR FLANGE.

11. Install the pinion oil seal with the appropriate tool:

a. Apply extreme pressure lithium soap grease to the oil seal lips.

INDUSTRIALADHESIVE

b. Apply 3M Industrial Adhesive or equivalent to the oil seal outer surfaces.

c. Press the oil seal into the bearing until the seal fl ange is fl at against the top of the bearing cage. Use the correct size sleeve or seal driver that fi ts against the seal metal fl ange. The diameter of the sleeve must be larger than the diameter of fl ange.

d. Install the yoke or fl ange and pinion nut into the pinion.

e. Tighten the pinion nut to the specifi ed torque after installing the pinion bearing cage into the main housing of 465-570 lbs. ft. (630-775 N·m).


30

Adjust Thickness of Pinion Bearing Cage Shim Pack (Depth of Pinion)NOTE: Use this procedure if a new drive pinion and ring gear set is installed or if the depth of the drive pinion has to be adjusted.

SHIMPACK

BEARINGCAGE

MAINHOUSING

1. Use a micrometer to measure the thickness of the old shim pack removed from under the pinion cage. Record the measurement for later use.

2. Record the pinion cone (PC) variation number on the old drive pinion being replaced. If the PC variation number cannot be located, assemble the gear set with the shim pack found in Step 1.

NOTE: The pinion cone number (PC) can be either 1,000ths of an inch (0.000 inch) or 100ths of a millimeter (0.00 mm).

Examples

PC+3, PC–3, +3 OR -3 = .003 inch (.076 mm)

PC+.03, PC–.03MM , + .03 OR –.03 = .03 mm

• To change inches to millimeters, multiply inches by 25.40.

• To change millimeters to inches, multiply millimeters by 0.039.

3. If the old pinion cone number is a plus (+), subtract the number from the old shim pack thickness measured in Step 2.

4. If the old pinion cone number is a minus (–), add the number to the old shim pack thickness measured in Step 2.

NOTE: The value calculated in Step 3 or 4 is the thickness of the standard shim pack without a variation.

5. Look at the pinion cone (PC) variation number on the new drive pinion being installed. Record the number for later use.

6. If the new pinion cone number is a plus (+), add the number to the standard shim pack thickness calculated in Step 3 or 4.


31

7. If the new pinion cone number is a minus (–), subtract the number from the standard shim pack thickness calculated in Step 3 or 4.

NOTE: The value calculated in Step 6 or 7 is the thickness of a new shim pack being installed.

EXAMPLES Inches mm

1.

Old shim pack thickness 0.030 0.76

Old PC number, PC+2 (+0.05mm) –0.002 –0.05

Standard shim pack thickness 0.028 0.71

New PC number, PC+5 (+0.13mm) +0.005 +0.13

New shim pack thickness 0.033 0.84

2.


Old PC number, PC–2 (–0.05mm) +0.002 +0.05


New PC number, PC+5 (+0.13mm) +0.005 +0.13


3.


Old PC number, PC+2 (+0.05mm) –0.002 –0.05


New PC number, PC–5 (–0.13mm) –0.005 –0.13

New shim thickness 0.023 0.58

4.


Old PC number, PC–2 (–0.05mm) +0.002 +0.05


New PC number, PC–5 (–0.13mm) –0.005 –0.13


Install Pinion Bearing Cage Assembly on Main HousingNOTE: Use a minimum of three shims in a pack. If a pack is made from diff erent thickness shims, install the thin-nest shims on both sides of pack for maximum sealing.

1. Install the correct shim pack between the bearing cage and main housing.

CAPSCREW

SHIM PACK

! WARNINGDO NOT STRIKE STEEL PARTS WITH A STEEL HAMMER DURING ASSEMBLY AND INSTALLATION PROCEDURES. PARTS CAN BREAK AND CAUSE SERIOUS PERSONAL INJURY.

2. Install the drive pinion and bearing cage into carrier. If necessary, use a rubber, plastic, or leather mallet to tap the assembly into position.


32

3. Install the two capscrews and washers fastening the bearing cage. Tighten to a minimum torque of 67 lbs. ft. (90 N·m).

4. Install the yoke or fl ange and pinion nut. Fasten the yoke or fl ange with the appropriate tool. Tighten the pinion nut to a minimum torque of 465-570 lbs. ft. (630-775 N·m).

! CAUTIONTHE FIT BETWEEN THE INPUT YOKE OR THE FLANGE SPLINES AND DRIVE PINION IS TIGHT. TO INSTALL THE YOKE OR FLANGE INTO THE PINION, USE THE PINION NUT AND AN APPROPRIATE TOOL TO FASTEN IT. NEVER USE A HAMMER OR MALLET. A HAMMER OR MALLET WILL DAMAGE THE YOKE OR FLANGE.

5. If the ring gear is mounted opposite from the brake housing side, loosen the two capscrews fastening the pinion bearing cage. Remove the cage and mount it after the diff erential case is assembled.

If the ring gear is mounted on the brake housing side, install the other capscrews fastening the pinion bearing cage. Tighten the capscrews to a torque of 67-91 lbs. ft. (91-120 N·m).


33

Install Diff erential Housing Assembly into Main Housing (with Shims)1. The preload of the diff erential bearings is adjusted by

selecting the proper shim pack to obtain a torque of 15-35 lbs. in. (1.7-4.0 N·m).

2. Install the shims. Combine two shims to obtain the desired thickness.

NOTE: Usually a 0.102-0.104 inch (2.60-2.65 mm) shim pack thickness is enough to obtain the proper backlash and diff erential bearing preload.

NUT

COUNTER NUT

3. Install the diff erential case bearing cup, axle shaft housing ,and brake housing studs into the main housing until the thread is completely attached. Apply liquid gasket material on the stud threads.

4. Install the diff erential case assembly.

5. Install the brake housing and the other diff erential case bearing cup.

6. Install three bolts to adjust the diff erential on the brake housing. Tighten to a torque of 19-26 lbs. ft. (26-36 N·m).

7. Install the diff erential case bearing adjusting nut on the brake housing.

8. Install the pinion bearing cage assembly and shim pack.

9. Check backlash, diff erential preload, and teeth contact. See "Adjustment" on page 46.


34

10. If all adjustments are within specifi cations, remove the brake housing. Apply liquid gasket material to the main housing surface.

11. Install three bolts into the brake housing to adjust the diff erential. Tighten to 19-26 lbs. ft. (26-36 N·m).

12. Apply Loctite 241 Medium-Strength Threadlocker to the lock capscrews. Install the adjusting nut lock and capscrews. Tighten capscrews to 80-115 lbs. in. (9-13 N·m).

Install Diff erential Housing Assembly into Main Housing (With Adjusting Ring 2 Sides)1. Install the adjusting ring into the main housing.

2. Install the bearing cup.

3. Install the diff erential case assembly into the main housing.

4. Install the brake housing and the other diff erential case bearing cup.

5. Install three bolts to adjust the diff erential on the brake housing. Tighten to 19-26 lbs. ft. (26-36 N·m).

6. Install the diff erential case bearing adjusting nut into the brake housing.

7. Install the pinion bearing cage assembly and the shim pack. See "Install Pinion Bearing Cage Assembly on Main Housing" on page 31.


35

8. Install the adjusting rings by:

a. Tightening the ring gear side adjusting ring to eliminate backlash between ring gear and pinion.

b. Unfastening the same adjusting ring from four to fi ve slots.

c. Tightening the opposite side adjusting ring to obtain a preload of 15-35 lbs. ft. (1.7-4.0 N·m). Discount the pinion bearing preload measured before.

9. Check the backlash, diff erential preload, and teeth contact. See "Adjustment" on page 46.

10. If all adjustments are within specifi cations, remove the brake housing. Apply liquid gasket material to the main housing surface.

11. Apply Loctite 271 High-Strength Threadlocker on the stud threads.

12. Install the studs fastening the brake housing and axle shaft housing to the main housing. Tighten studs until resistance is met.

13. Install the bearing cup and brake housing into the main housing. Align holes at the mark made during disassembly.

14. Install 3 bolts into the brake housing to adjust the diff erential. Tighten to 19-26 lbs. ft. (26-36 N·m).

15. Apply Loctite 241 Medium-Strength Threadlocker to the lock capscrews. Install the adjusting nut lock and capscrews. Tighten capscrews to 80-115 lbs. in. (9-13 N·m).

Assemble Axle Shaft1. Use the correct size sleeves to install the cups into the

axle shaft housing bores until the cups are fl at against the bottom of the bores.

2. Install the Duo-Cone oil seal into the axle shaft and into the axle shaft housing bore. See "Duo-Cone Oil Seal Assembly" on page xi.

DUO-CONEOIL SEAL

3. Using a press and the correct size sleeve, install the fl ange side cone bearing. Install the axle shaft into the axle shaft housing.


36

Assemble Trumpet Assembly! WARNING

OBSERVE ALL WARNINGS AND CAUTIONS PROVIDED BY THE PRESS MANUFACTURER CONCERNING PRESS OPERATION TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO COMPONENTS DURING ASSEM-BLY AND INSTALLATION PROCEDURES.

1. Use a press to install a new planetary pin into the spider. Ensure the proper dimensions are used and the holes are aligned.

ALIGNEDHOLES

44.6044.80

2. Apply Loctite 241 Medium-Strength Threadlocker to the threads of the planetary gear axle lock capscrews. Install and tighten to 17-23 lbs. ft. (23-31 N·m).

! CAUTIONROLLERS MUST COME FROM THE SAME MANUFACTUR-ER AND HAVE THE SAME TOLERANCE RANGE. REPLACE SPACERS AND WASHERS WHEN A NEW ROLLER IS USED.

3. Apply grease, Shell-71032 Alvania EP-2 or Texaco - 995 Multifak EP-2, on each gear hole. Install the rollers and spacers into the planetary gears.

4. Install the bearing cone.

5. Install the planetary spider and the axle shaft bearing adjusting nut.


37

6. Measure the trumpet fl ange radius. With a spring scale, check the trumpet assembly preload before tightening the adjusting nut.

The value will be obtained by multiplying the number read on the spring scale dial by the fl ange radius. Make note of the value.

7. Tighten the adjusting nut with the special tool shown on page 62. At the same time, manually rotate the trumpet to ensure a correct fi t between the bearing cups and cones and obtain the desired preload.

8. Check the trumpet assembly preload and subtract the value obtained before tightening the adjusting nut. The value must be between 15-35 lbs. in. (1.7-4 N·m).

9. Apply Loctite 241 Medium-Strength Threadlocker on the adjusting nut lock capscrew threads. Install adjusting nut lock capscrew and tighten to 17-23 lbs. ft. (23.0-30.5 N·m).

10. Install the inner washer, planetary gears, and rollers into the fl ange.

11. Install the outer washers.

12. Using the correct pliers, install the snap rings.


38

13. Apply liquid gasket material on the contact surfaces of the trumpet and ring.

GASKET

14. Install the ring gear into the trumpet. Use reference marks made during disassembly to align the holes to the contact surface.

Assemble Hydraulic Apply Brake Housing AssemblyNOTE:

• To assemble the three function brake, see page 40.

• To assemble the ball and ramp brake, see page 44.

1. Check to see if the piston lodging surfaces on the brake housing is free of sharp edges, nicks, and burrs. Repair any damage or replace the part.

2. Repeat Step 1 on the outer surfaces of the brake piston.

3. Apply a thin fi lm of oil, SAE W140 or SAE 90, to the piston and bore. Apply a dense layer of oil to the brake housing chamfer.

4. Carefully install the piston oil seals.

NOTE: Before pressing the piston into the brake housing, rotate the piston 15° to 20°. If the piston does not turn easily, disassemble and fi nd the cause of the interference.

5. With a manual press, carefully install the piston into the brake housing. Do not damage the oil seals. If there is resistance installing the piston, do not proceed until the issue is resolved.

BRAKEHOUSING

RETURNSPRING

SPRINGCAPSCREW

BRAKEPISTON OIL

SEAL


39

6. Apply Loctite 271 High-Strength Threadlocker to the capscrew threads. Install the return springs and return spring capscrews. Tighten to 80-115 lbs. in. (9.0-13.0 N·m).

Hydraulic Apply Brake Housing Functional TestNOTE:

• This test procedure is only for the hydraulic apply brake system.

• To perform this test, it is necessary to use a device which permits the observation of possible leaks through the oil seals and if the piston return system is working. For an accurate evaluation, the device must allow a piston displacement of 0.157-0.197” (4-5 mm).

1. Connect the brake housing assembly to a hydraulic system equipped with a 1000 psi (69 bar) manometer.

2. Activate the cylinder at least fi ve times with 600 psi (41.4 bar). Check for leaks.

• If there are no leaks, proceed to Step 3.

• If there are leaks, disassemble the brake housing assembly, then locate and correct the problem.

3. Wait fi ve minutes, then apply 600 psi (41.4 bar) to the cylinder again.

• If there are no leaks, proceed to Step 4.

• If there are leaks, disassemble brake housing assembly, then locate and correct the problem. Repeat Steps 1 to 3.

4. Wait fi ve minutes, then apply 75 to 110 psi (5.1 to 7.6 bar) to the cylinder again.

• If there are no leaks, the assembly is built correctly.

• If there are leaks, then locate and correct the problem. Repeat the test again.


40

Assemble Three Function Brake Housing AssemblyNOTE: Before assembling the brake housing assembly, ensure all surfaces and bores of the brake housing and piston are free of dirt, burrs, and nicks.

1. Select the piston shim pack using the following procedure:

a. Position the piston assembly parts into a press. Measure the dimension “A” under 441 lbs. (200 kg) pressure.

“A”

441 lbs (200 Kg)

PISTON

WITHOUTSPRINGS

ACTION PLATE

BRAKE DISCS

REACTIONPLATE

b. Measure the dimension “B”.

“B”

c. The shim pack thickness is the diff erence between dimension “B” and dimension “A” minus 0.06 in. (1.5 mm):

B - A -0.06 in. (1.5 mm) = shim pack thickness

d. If the brake piston is assembled, the shim pack thickness, under press pressure of 441 lbs (200 Kg), is the diff erence between dimension “B” minus the sum of dimensions “C” and “D” minus 0.06 in. (1.5 mm):

B - (C + D) -0.06 in. (0.15) = shim pack thickness

“C”

600 lb (300 Kg)

250 lb (113 Kg)BRAKE DISCS

PLATE

“D”

2. Lubricate the internal brake housing surfaces, inner and outer piston surfaces, and oil seal bores with SAE 90 oil.

INNERPISTON

OUTERPISTON

LARGEOIL

SEAL

OILSAE 90

MEDIUMOIL SEAL

SMALLOIL SEAL

NOTE: Each piston assembly has three diff erent sizes of oil seals: three large, one medium, and one small.

3. Install the medium oil seal into the inner piston bore and install the small oil seal into the outer piston bore.

4. ONLY use a manual press to install the inner piston into the outer piston. Be careful not to damage the oil seals. Do not force the inner piston assembly.

PRESSMARKS

NOTE: Rotate pistons until marks are aligned. If inner piston does not rotate easily, disassemble it and fi nd the cause.


41

5. Install the springs into the bores of the inner piston.

For brakes with 12 springs, jump one bore each three.

6. Install the compression plate on the piston. Correctly align the fastener holes. Use marks on the piston and lock pin slot.

COMPRESSIONPLATEPISTON

MARKS

7. Apply pressure to the compression plate until it is fl at against the piston.

8. Apply Loctite 241 Medium-Strength Threadlocker into the threaded external piston bolt holes. Install the action plate bolts as shown and apply a pre-torque of 30 lbs. in. (3.3 N·m). Tighten to a torque of 120-140 lbs. in. (13.5-16 N·m).

3

2

4

1

9. Install the three larger oil seals into the outer piston. Ensure the oil seals fi t in the bores.

LARGER OIL SEALS

10. Install the shim pack into the brake housing. Use bolts to align the holes.

GUIDEBOLTS

SHIMS

11. Remove the guide bolts and manually install the brake piston assembly into the brake housing. Rotate the piston assembly 15° to 20° The rotation must be easy and without resistance. If there is any resistance, disassemble the brake piston assembly and fi nd the cause.

12. Use bolts as a guide and align the piston and holes. Use the marks made during disassembly as reference.

13. With a manual press on the brake housing, apply pressure to the brake piston until the springs compress. Ensure the oil seals fi t into the bores.


42

14. With the piston still compressed, apply 350 psi (24 bar) into the parking brake to ensure the oil seals fi t in the bores.

350 PSI (24 BAR)

15. Keep the parking brake under 350 psi (24 bar) pressure and remove the manual press and guide pins.

16. Apply Loctite 241 Medium-Strength Threadlocker to the return spring holes and bolt threads. Install the return springs, washers, and return spring bolts into brake housing. Tighten bolts to 80-115 lbs. in. (9-13 N·m).

350 PSI(24 BAR)

BOLT WASHER

SPRING

17. Use the same procedure to install the other brake piston assemblies into the main housing.

Assemble Ball and Ramp Brakes, Brake Discs, Reaction Plate & Pins1. Install the sun gear.

NOTE: After assembly, the friction disc lubrication holes must be perfectly aligned.

2. Install the friction and stationary discs alternately. Ensure the friction disc is against the brake piston.

3. For ball and ramp brakes, the discs must be installed alternately and a friction disc must be on each side of the expansive plate.

STATIONARY DISCFRICTION DISC

REACTION PLATE

FRICTION DISC

SPACER

EXPANSIVE PLATE

PIN

4. Install the stationary disc lock pins.

5. Install the reaction plate with the lubrication hole on the down side of the axle.

6. If there is an outer spacer, install it onto the brake housing surface. Use a liquid gasket material.


43

Assemble Three Function Brakes, Brake Discs, Reaction Plate & Pins1. Lubricate all brake components with the same oil

specifi ed for axle. See "Lubricant Specifi cations" on page 53.

2. Install the sun gear.

3. Apply 350 psi (24 bar) into the parking brake.

4. Install the friction and stationary discs, guide pins, and the reaction plate.

REACTION PLATE

BRAKEHOUSING

PIN

FRICTION DISCS

STATIONARYDISCS

Install Housing Assembly into Main HousingNOTE: If the axle is equipped with a three function brake, keep the parking brake pressurized.

1. Install the housing assembly. Ensure the mark made during disassembly is correctly positioned to align the fastener holes.

2. Install the capscrews and nuts fastening the housing to the main housing.

• Tighten grade 12.9 capscrew 170-200 lbs. ft. (230-271 N·m)

• Tighten grade 10.9 capscrew 135-170 lbs. ft. (183-230 N·m)

• Tighten stud nuts 120-150 lbs. ft. (160-205 N·m)

3. Release pressure from the parking brake.

4. Apply Loctite 515 Flange Sealant on the cover surface touching the main housing and on the capscrew threads. Install the cover and capscrews to the main housing. Tighten capscrews to 20-27 lbs. ft. (27-36 N·m).


44

Assemble Three Function Brake Release Bolts & Sleeves1. Apply Loctite DRI 516 to the bolt threads.

LOCTITE 516 SILASTIC 780 RTV

2. Apply liquid gasket material, Silastic 780 RTV Dow Corning, on the non-threaded bolt shaft.

3. Install the bolts and sleeves. Tighten to a minimum torque of 25-34 lbs. ft. (34-46 N·m).

• Assemble 2 larger bolts, 3.346” (85 mm) with larger sleeves, 1” (26 mm)

• Assemble shorter bolt, 3.070” (78 mm) with shorter sleeve, 0.750” (19 mm)

BRAKEHOUSING

RING GEAR SLEEVE

SHORT BOLT ANDSLEEVE INTO THISPOSITION

BOLT

PIN

Assemble Ball and Ramp Brake Cylinder Assembly & Install on Main Housing1. Apply liquid gasket material on the brake cylinder

surface touching the brake cylinder support. Assemble the brake cylinder, oil seals, piston, and brake cylinder support. Tighten the capscrews fastening the brake cylinder support to 19-26 lbs. ft. (26-36 N·m).

NOLIQUIDGASKETMATERIALHERE

2. While out of the axle, connect the cylinder assembly to the hydraulic system. Apply 400 psi (27.6 bar) pressure to compress the spring until the piston is against the brake cylinder. Repeat this operation four to fi ve times to make sure there is no leakage.

HYDRAULICPRESSURE


45

! CAUTIONDO NOT USE BRAKE FLUID IN THE HYDRAULIC SYSTEM. USE SHELL DONAX TD OR SHELL TELLUS 32 OR EQUIV-ALENT.

3. Install the brake cylinder assembly onto the main housing.

CYLINDERCAPSCREW

SUPPORTCAPSCREW

4. While the cylinder is pressurized with 400 psi (27.6 bar), apply Loctite 221 Low-Strength Threadlocker on the brake shaft threads. Install the adjusting nut until it rests against the piston. DO NOT TIGHTEN THE ADJUSTING NUT. Loosen the adjusting nut one full turn.

BRAKESHAFT

ADJUSTING NUTRETURN 1 LAP

HYDRAULICPRESSURE

5. Release the cylinder pressure to ZERO so the piston returns back against the adjusting nut. Check the dimension “X” as shown in the illustration below.

BRAKE SHAFT

ADJUSTING NUT

WITHOUTPRESSURE

“X”=1.47 inch (37.0 mm)

If dimension “X” is smaller than 1.47” (37.0 mm), tighten the adjusting nut until the dimension is reached. If the dimension is larger, unfasten the nut. This adjustment must be made with the piston activated.

6. After the 1.47” (37.0 mm) dimension is obtained, apply the specifi ed pressure to the brake and check the brake torque on the pinion as shown in the chart.

Torque Reduction

Disc No.

Pressure Torque

PRA-382 17.08:1

06 275 psi min (19 bar min)

950-1200 lbs. ft. (1288.0-1559.0 N·m)

PRA-353 46.00:1

06 275 psi min (19 bar min)

350-500 lbs. ft. (474.5-678.0 N·m)

NOTE: To obtain the desired brake torque, fasten or unfas-ten the adjusting nut. For each 0.04 inch (1 mm) turned on dimension “X”, the variation in torque is 4%.

Adjustment

46

7. After obtaining the desired brake torque, install the nut lock as shown in the illustration below. Tighten to 60-90 lbs. in. (80-120 N·m).

LOCK NUT

ADJUSTINGNUT

WITHOUTPRESSURE

“X”=1.47 inch(37.0 mm)

DIM. “Y”

8. Install the cover.

ADJUSTINGNUT

SPRING

PISTON

O-RING

CYLINDERSUPPORT

CYLINDER

WITHOUTPRESSURE

O-RING

LOCK NUT

COVER

9. The dimension “Y” must be equal with ± 0.02 inch (0.5 mm) on each side. If the dimension is larger on one of the sides after adjustment, disassemble and fi nd the cause.

NOTE: Do not check the brake torque before the wheel has turned at least two times with the brake activated.

Adjustment

Check Ring Gear RunoutSpecifi cation: 0.008 inch (0.20 mm)

! WARNINGALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE EQUIPMENT TO PREVENT PERSONAL INJURY WHEN PERFORMING VEHICLE SERVICE.

1. Attach the magnetic base of a dial indicator to the mounting fl ange of the main housing.

2. Set the dial indicator so the plunger or pointer is against the back surface or ring gear.

3. Set the dial indicator to ZERO.

4. Rotate the diff erential and ring gear assembly while reading the dial indicator. Ring gear runout must not exceed 0.008 inch (0.20 mm). If runout exceeds specifi cations, remove the diff erential and ring gear assembly from the main housing.

5. Check the diff erential parts including the carrier for problems causing ring gear runout to exceed specifi cations. Repair or replace parts, if necessary.

! CAUTIONSHOCK LOAD FAILURE WILL DISTORT THE DIFFEREN-TIAL CASE FLANGE AND TRANSFER DAMAGE TO THE RING GEAR. IN THIS CASE, THE DIFFERENTIAL CARRIER MUST BE DISCARDED.

6. After parts are repaired or replaced, install main diff erential case and ring gear assembly into carrier. Repeat Steps 1 to 5.

Adjustment

47

Adjust Pinion and Ring GearBacklash Specifi cation: 0.005-0.015” (0.13-0.38 mm)

1. Attach the dial indicator on the carrier mounting fl ange.

2. Set the dial indicator so the lunger is against a tooth surface.

3. Set the dial indicator to ZERO.

NOTE:

• When adjusting backlash, only move the ring gear. Do not move the drive pinion.

• If using an old ring gear and pinion, it is recom-mended the original backlash is maintained.

4. Hold the drive pinion in position.

5. While reading the dial indicator, rotate the diff erential and the ring gear a small amount in both directions against the teeth of the drive pinion. If the backlash reading is within the specifi ed range of 0.005-0.015” (0.13-0.38 mm), continue by checking the tooth contact patterns. If the backlash reading is not within specifi cations, adjust the backlash as needed.

6. Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount to keep the diff erential roller bearing preload.

INCREASEBACKLASH

DECREASEBACKLASH

NOTE: When adjusting backlash, only move the ring gear. Do not move the drive pinion.

• Backlash is increased by moving the ring gear away from the drive pinion.

• Backlash is decreased by moving the ring gear toward the drive pinion.

7. Repeat Steps 2 through 6 until backlash is within specifi cations. Record the setting used when adjusting the pinion bearing preload.

Adjustment

48

Teeth Contact PatternsIn the following procedures, movement of the contact pat-tern along the length of the tooth is indicated as toward the “heel” or “toe” of the ring gear.

CONCAVESIDE

CONVEXSIDE

TOP

BOTTOM

HEEL

TOE

TOE

HEEL

Verifi cation Procedure1. Apply a marking compound to approximately 12 teeth

of ring gear. Rotate the ring gear so the 12 gear teeth are next to the drive pinion.

2. Apply load on the ring gear with a wood pry bar. Rotate the gear forward and backward so 12 gear teeth go past the drive pinion six times to obtain a contact pattern. Repeat, if needed, to get a clearer pattern.

3. Compare the contact patterns on the ring gear teeth to the illustrations in "Correct Contact Patterns" on page 49 and "Incorrect Contact Patterns" on page 50.

Adjustment

49

Correct Contact PatternsThe location of a good hand-rolled contact pattern for a new gear set is toward the toe of the gear tooth and in the center, between the top and bottom of the tooth.

When the carrier is being operated under load, the pattern will extend approximately the full length of tooth. The top of the pattern will be near the top of the gear tooth.

The location of a good hand-rolled pattern for a used gear set must match the wear pattern in the ring gear. The con-tact pattern will be smaller in area than the wear pattern.

An acceptable contact pattern is centralized between the toe and heel along the length of gear teeth.

In cases where it is not possible to get a good contact pattern, the contact pattern above is acceptable. If the acceptable contact pattern is not achieved, change the ring gear and pinion set.

The illustration below also indicates a good contact pat-tern. It is toward the toe and centralized between the top and bottom of the gear teeth.

Adjustment

50

Incorrect Contact Patterns

High Contact PatternA high contact pattern indicates the drive pinion was not installed deep enough into the carrier.

• To correct a high contact pattern, decrease the thickness of the shim pack under the bearing cage. This will move the drive pinion toward the ring gear.

DECREASE SHIMPACK THICKNESS

Deep Contact PatternA deep contact pattern indicates the drive pinion was installed too far into the carrier.

• To correct a deep contact pattern, increase the thickness of the shim pack under the bearing cage. This will move the drive pinion away from the ring gear.

INCREASE SHIMPACK THICKNESS

Adjustment

51

Variations Along Length of Gear TeethAdjust the ring gear backlash within the specifi ed range to move the contact pattern to the correct location along the length of the gear teeth.

When the toe contact pattern indicates backlash is very low and the gear is too close to the drive pinion:

• Withdraw the ring gear by decreasing the shim pack thickness or loosening the gear side adjusting ring and tightening the opposite side adjusting ring.

When the heel contact pattern indicates backlash is very high and the gear is too far away from the drive pinion:

• Move the ring gear closer by increasing the shim pack thickness or loosening the opposite side adjusting ring and tightening the gear side adjusting ring.

Lubrication

52

Lubrication

Lubricant Replacement1. Install and tighten the drain plug in the central

housing and the brake housing.

2. Clean the area around fi ll/level plug. Remove the fi ll/level plug from the carrier inspection cover.

! CAUTION• USE ONLY THE TYPE OF FLUID SPECIFIED BY THE EQUIPMENT MANUFACTURER. DO NOT USE OR MIX DIFFERENT TYPES OF FLUID. THE WRONG FLUID WILL DAMAGE THE RUBBER PARTS OF THE ASSEMBLIES WHICH COULD CAUSE LOSS OF BRAKING AND SERI-OUS PERSONAL INJURY.

• DO NOT REUSE FLUID. USED FLUID CAN BE CON-TAMINATED AND CAN CAUSE INCORRECT OPERATION WHICH COULD RESULT IN SERIOUS PERSONAL INJURY.

3. Add the specifi ed oil until the oil level is even with the bottom of the fi ll/level hole.

4. Install and tighten the fi ll/level plugs.

5. Road test the vehicle in an unloaded condition for one-two miles (1.6-3.2 km) at speeds not more than 25 mph (40 kph).

6. Check the lubricant levels and the torque of all the fasteners.

! CAUTION• THE OPERATING TEMPERATURE OF THE COOLANT MUST NEVER REACH OR EXCEED 250°F (120°C). IF THE OPERATING TEMPERATURE OF THE COOLANT REACHES OR EXCEEDS 250°F (120°C), THE INTERNAL COMPONENTS OF THE BRAKE WILL BE DAMAGED. A FORCED COOLING SYSTEM MAY BE REQUIRED TO AS-SURE THE COOLANT TEMPERATURE REMAINS BELOW 250°F (120°C).

• USE ONLY THE BRAKE HYDRAULIC FLUID SPECIFIED BY THE MANUFACTURER OF THE VEHICLE. DO NOT USE DIFFERENT HYDRAULIC FLUIDS. THE WRONG FLUID WILL DAMAGE THE SEALS ON THE PISTON.

Lubrication

53

Lubricant Specifi cationsOff -Highway Operation Intervals* AxleTech

Specifi cationMilitary

Specifi cationOil

DescriptionInitial Oil Change Check Oil Level Petroleum Oil Change

Synthetic Oil Change

100 operating hours* or 1240-3100 miles (2000-5000 km) (whichever comes fi rst)

250 operating hours* 1,500 operating hours or twice a year (whichever comes fi rst)

— 0-84 — Mobile 424†

NOTE:* The checking interval depends on the individual operating conditions, speeds and loads. Severe operating conditions may require more frequent intervals.

† Tractor oil universal fl uid, ‘TOU’ types formulated for wet disc brakes, is recommended for use in the wet disc brake housing. Ensure the specifi cations of the tractor fl uid are the same as the recommended specifi cations of the vehicle manufacturer.

Appendix

54

Appendix

Torque Specifi cations

Appendix

55

56

PROA 352/382

(With Mechanical Drive Option)

4

2

717

18

13

9

12

6

8

5

1 3

19

14

11

15

16

10

57

EUQROTDAERHT/NOITPIRCSEDMETI)m•N 577-036( tf-bl 075-564H6-5.1 x 42M - tuN noiniP1)m•N 502-061( tf-bl 051-021H6-5.1 x 41M )gnisuoH retneC - dutS( tuN2

)m•N 78-46( tf-bl 46-84G8-5.1 x 01M )esaC laitnereffiD( wercspaC3)m•N 001-09( tf-bl 57-66G6-0.1 x 01M )raeG laripS( wercspaC4)m•N 021-19( tf-bl 19-76G8-57.1 x 21M )egaC noiniP( wercspaC5

)m•N 0.31-0.9( ni-bl 511-08G6 6M )gniR retsujdA kcoL( wercspaC6)m•N 03-32( tf-bl 32-71G6-52.1 x 8M)kcoL tuN gnitsujdA( wercspaC7)m•N 63-62( tf-bl 62-91G6-52.1 x 8M)gnisuoH ekarB( wercspaC8)m•N 64-43( tf-bl 43-52G6-57.1 x 21M)resaeleR ekarB( wercspaC9

10 Capscrew (Flange Adapter) .3750” x 16UNC2A 39.0-53.0 lb-ft (53-72 N•m)11 Capscrew (Center Housing Cover) M8 x 1.25-6G 20-27 lb-ft (27-36 N•m)

)m•N 087-536( tf-bl 575-074G6-5.1 x 02M)egnalF tfahS elxA( wercspaC21)m•N 74( tf-bl 53gulP niarD31

)m•N 5.4-5.3( ni-bl 04-13gnittiF esaerG41)m•N 02( tf-bl 51gulP tneV51)m•N 74( tf-bl 53gulP leveL61

17 Capscrew (Planetary Pinion Axle) M10 x 1.5-6G 17-23 lb-ft (23-31 N•m))m•N 0.61-5.31( ni-bl 041-021G6-5.1 x 6M)etalP noitcA( tloB81

)m•N 0.31-0.9( ni-bl 511-08G6-0.1 x 6M)gnirpS nruteR( wercspaC91

58


4

13

6

1

3

10

2

8

12

118

7

9

2

59

EUQROTDAERHT/NOITPIRCSEDMETI)m•N 577-036( tf-bl 075-564H6-5.1 x 42M - tuN noiniP1)m•N 052-502( tf-bl 581-051G6-5.1 x 41M - )gnisuoH retneC( wercspaC2)m•N 502-061( tf-bl 051-021H6-5.1 x 41M - )gnisuoH retneC - dutS( tuN3

)m•N 78-46( tf-bl 46-84G6-5.1 x 01M - )esaC laitnereffiD( wercspaC4)m•N 001-09( tf-bl 57-66G6-0.1 x 01M - )raeG laripS( wercspaC5)m•N 521-09( tf-bl 19-76G6-57.1 x 21M - )egaC noiniP( wercspaC6

)m•N 31-9( ni-bl 511-08G6-6M - )gniR retsujdA - kcoL( wercspaC78 Capscrew - Adjusting Nut Lock - M8 x 1.25-6G 17-23 lb-ft (23-31 N•m)

)m•N 0.31-0.9( ni-bl 511-08G6-0.1 x 6M - gnirpS nruteR - tloB910 Capscrew (Planetary Pinion Axle) - M10 x 1.5-6G 17-23 lb-ft (23-31 N•m)

).nim m•N 74( .nim tf-bl 535.1 x 42M - leveL - gulP11).nim m•N 74( .nim tf-bl 535.1 x 42M - niarD - gulP21).nim m•N 02( .nim tf-bl 515.1 x 21M - tneV - gulP31

60

PROA 352 G2H, G2M

5

20

19

16

21

18

6

1

15

13

11

10

48

3

2

17

13

12

14

11

10

9

7

22

2

17

14

61

EUQROTDAERHT/NOITPIRCSEDMETI)m•N 577-036( tf-bl 075-0.564H6-5.1 x 42M - tuN noiniP1

)m•N 092-542( tf-bl 0.512-0.081G6-5.1 x 41M )gnisuoH retneC( wercspaC2)m•N 502-061( tf-bl 051-021H6-5.1 x 41M )gnisuoH retneC - dutS( tuN3

)m•N 78-46( tf-bl 46-84G6-5.1 x 01M )esaC laitnereffiD( wercspaC4)m•N 001-09( tf-bl 57-66G6-0.1 x 01M )raeG laripS( wercspaC5

)m•N 021-19( tf-bl 0.19-0.76G6-57.1 x 21M)egaC noiniP( wercspaC6)m•N 31-9( ni-bl 0.511-0.08G6 6M)gniR retsujdA kcoL( wercspaC7

)m•N 13-32( tf-bl 32-71G6-52.1 x 8M)kcoL tuN gnitsujdA( wercspaC8)m•N 63-62( tf-bl 62-91G6-52.1 x 8M)gnisuoH ekarB( wercspaC9

10 Capscrew (Brake Cylinder Support) M8 x 1.25-6G 19-26 lb-ft (26-36 N•m))m•N 78-46( tf-bl 46-84G6-5.1 x 01M)rednilyC ekarB( wercspaC11)m•N 021-08( tf-bl 09-06G6-5.1 x 08M)rednilyC ekarB( revoC21

13 Capscrew (Brake Cylinder Cover) M12 x 1.75-6G 22-30 lb-ft (30-41 N•m))m•N 14-03( tf-bl 03-22G6-57.1 x 21M )resaeleR ekarB( wercspaC41

15 Capscrew (Flange Adapter) .3750" x 16UNC2A 39.0-53.0 lb-ft (53-72 N•m)16 Capscrew (Center Housing Cover) M8 x 1.25-6G 19-26 lb-ft (26-36 N•m)

)m•N 087-536( tf-bl 575-074G6-5.1 x 02M)egnalF tfahS elxA( wercspaC71)m•N 74( tf-bl 0.53gulP niarD81)m•N 41( tf-bl 0.01gnittiF esaerG91

).nim m•N 02( .nim tf-bl 0.51gulP tneV02).nim m•N 74( .nim tf-bl 0.53gulP leveL12

22 Capscrew (Planetary Pinion Axle) M10 x 1.5-6G 17.0-23.0 lb-ft (23-31 N•m)

62

Tools

Nut Lock Tool

Ø 3.86 in.(Ø 98.0 mm)

Ø 0.709 in.(Ø 18.0 mm)

30°±10'

0.079 in.(2.0 mm)

Ø 0.547 in.

(Ø 13.9 mm)

13.8

15.55 in.(395.0 mm)

THREAD: Ø 5/8" II UNC

13.78 in.(350.0 mm)

0.079 in.(20.0 mm)

0.197 in.(5.0 mm

x 45°)

1.77 in.(45.0 mm)

0.57 in.(14.5mm)0.078 in.

R 2.0

0.984 in.R 5.0

Ø 3.15 in.(Ø 80.0 mm)

Ø 0.79 in.(Ø 20.0 mm)

Ø 1.97 in.(Ø 50.0 mm)

0.39 in.(10.0 mm x 45°)

4.53 in.(115.0 mm)

2.44 in.(62.0 mm)

1.77 in.(45.0 mm)

© 2019 AxleTech International LLC. All rights reserved. AxleTech and AxleTech International are registered trademarks of AxleTech International LLC.All other brands and product names are trademarks or registered trademarks of their respective owners. Information supplied by AxleTech is believed to be accurate and reliable. AxleTech reserves the right, without notice, to makes changes in product design or specifications.

Customer Service 877-547-3907+33 (0) 4 77 92 88 92

Customer Service Fax877-547-3987

Email OE: [email protected]: [email protected]

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