AxleTech PRC 785P, PRC 485Q, PRC 785 W3H, PRC 485 W3H planetary axle Maintenance Manual

Planetary Axle Wheel Ends

Extrémité de roue à réduction planétaire

Maintenance Manual 9N

Manuel de maintenance 9N

Issued 03-07

Edité Marche 07

Models/Módeles

PRC 785P/485Q

PRC 785P/485Q W3H

Service Notes

Before You Begin

This maintenance manual describes the correct service and repair procedures for all AxleTech planetary axle models listed on front cover. The information contained in this manual was current at time of printing and is subject to change without notice or liability.

You must follow your company procedures when you service or repair equipment or components. You must understand all procedures and instructions before you begin to work on a unit. Some procedures require the use of special tools for safe and correct service.

Failure to use special tools when required can cause serious personal injury to service personnel, as well as damage equipment and components.

AxleTech International uses the following notations to warn the user of possible safety problems and to provide information that will prevent damage to equipment and components.

Safety Alerts, Torque Symbol and Notes

!

WARNING

A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury.

!

CAUTION

A Caution alerts you to an instruction or procedure that you must follow exactly to avoid damage to components.

The torque symbol alerts you to tighten fasteners to a specified torque value.

NOTE:

A Note provides information or suggestions that help you correctly service a component.

The instructions contained in this Field Maintenance

Manual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair and replacement of the AxleTech product described herein. Installation, maintenance and replacement of such products require 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 to or death of persons and/or possible future or additional axle 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 installation, maintenance or replacement of the product described 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.

Additional Publications

For AxleTech service manuals, please contact:

1-877-877-9717 and 248-816-5401 or visit our website at www.axletech.com.

How To Order

Order items from AxleTech International.

Phone orders are also accepted by calling AxleTech

International’s Customer Service Center at

877-547-3907 or send a fax to 866-547-3987.

Table of Contents

!

Asbestos and Non-Asbestos Fibers Warnings

..........................................................................1

Section 1: Exploded Views

PRC 485Q (with Q Plus™ Cam Brakes).........................................................................................................2

PRC 485 W3H.................................................................................................................................................3

PRC 785P .......................................................................................................................................................4

PRC 785 W3H.................................................................................................................................................5

Section 2: Introduction

Description ......................................................................................................................................................6

Identification ....................................................................................................................................................7

Section 3: Disassembly

PRC 485Q (with Q Plus™ Cam Brakes) Wheel End Cross Section

PRC 485 Q Plus™ Cam Brake Planetary Axle Wheel End.......................................................................8

Brake Drum................................................................................................................................................8

Planetary Spider Assembly .....................................................................................................................10

Cam Brakes.............................................................................................................................................11

Spindle and Brake Spider........................................................................................................................11

PRC 485 W3H Wheel End Cross Section

PRC 485 W3H Wet Disc Brake Wheel End.............................................................................................13

Preliminary Disassembly .........................................................................................................................13


Wheel End ...............................................................................................................................................15

Spindle and Piston Housing ....................................................................................................................15

Wet Disc Brakes ......................................................................................................................................16

PRC 785P Wheel End Cross Section

PRC 785P Planetary Axle Wheel End.....................................................................................................17

Brake Drum..............................................................................................................................................17


Cam Brakes.............................................................................................................................................20

Spindle and Brake Spider........................................................................................................................20


PRC 785 W3H Wet Disc Brake Wheel End.............................................................................................21

Preliminary Disassembly .........................................................................................................................21


Wheel End ...............................................................................................................................................23

Spindle and Piston Housing ....................................................................................................................23

Wet Disc Brakes ......................................................................................................................................24


Section 4: Prepare Parts for Assembly

Clean Ground or Polished Parts....................................................................................................................25

Clean Parts with a Rough Finish...................................................................................................................25

Clean Axle Assemblies..................................................................................................................................25

Dry Cleaned Parts.........................................................................................................................................25

Prevent Corrosion .........................................................................................................................................25

Inspect Parts .................................................................................................................................................26

Inspect Tapered Roller Bearings...................................................................................................................26

Inspect the Bevel Pinion and Ring Gear Sets ...............................................................................................27

Inspect the Main Differential Assembly .........................................................................................................28

Inspect the Axle Shafts..................................................................................................................................28

Inspect the Yoke............................................................................................................................................28

Inspect the Brakes ........................................................................................................................................28

Repair or Replace Parts................................................................................................................................28

Repair Welding..............................................................................................................................................28

Apply Silicone Gasket Material......................................................................................................................29

Section 5: Assembly

PRC 485Q (with Q Plus™ Cam Brakes) Planetary Axle

PRC 485Q (with Q Plus™ Cam Brakes) Planetary Axle Wheel End ......................................................30

Prepare Parts for Assembly ....................................................................................................................30

Spindle, Brake Spider and Brake ............................................................................................................30

Wheel End ..............................................................................................................................................31

Adjust the Wheel Bearing Preload ..........................................................................................................32

Planetary Spider and Gearing Assembly ................................................................................................32

Final Assembly........................................................................................................................................33

PRC 485 W3H Wet Disc Brake

PRC 485 W3H Wet Disc Brake Wheel End ............................................................................................34


Spindle and Piston Housing to the Axle Housing....................................................................................34

Wet Disc Brakes......................................................................................................................................34

Wheel End ..............................................................................................................................................35

Toric Ring Face Seal into Wheel Hub and Disc Brake Housing..............................................................37

Check for Correct Installation of the TRS Toric Ring Seal ......................................................................39

Wheel Hub to Spindle Assembly ............................................................................................................40



Final Assembly........................................................................................................................................42

Fill Wet Disc Brakes with Hydraulic Fluid................................................................................................42

PRC 785P Planetary Axle

PRC 785P Planetary Axle Wheel End ....................................................................................................43


Spindle, Brake Spider and Brake ............................................................................................................43

Wheel End ..............................................................................................................................................44



Final Assembly........................................................................................................................................46



PRC 785 W3H Wet Disc Brake Wheel End ............................................................................................47


Spindle and Piston Housing to the Axle Housing....................................................................................47

Wet Disc Brakes......................................................................................................................................47

Wheel End ..............................................................................................................................................47

Toric Ring Face Seal into Wheel Hub and Disc Brake Housing..............................................................49

Check for Correct Installation of the TRS Toric Ring Seal ......................................................................51

Wheel Hub to Spindle Assembly ............................................................................................................52



Final Assembly........................................................................................................................................54

Fill Wet Disc Brakes with Hydraulic Fluid................................................................................................54

Section 6: Specifications

PRC 485 Q Plus™ Wheel End Torque Chart................................................................................................55

PRC 485 W3H Wheel End Torque Chart......................................................................................................56

PRC 785P Wheel End Torque Chart ............................................................................................................57

PRC 785 W3H Wheel End Torque Chart......................................................................................................58

Lubrication Specifications..............................................................................................................................59

Lubrication Schedule ....................................................................................................................................59

Wet Disc Brake Coolant Specifications ........................................................................................................60

Sump and Forced Cooling Systems With Hub Seals....................................................................................60

Coolant Change Intervals..............................................................................................................................60

Hydraulic Fluid Specifications ......................................................................................................................60

Section 7: Special Tools

Spindle Nut Tool............................................................................................................................................61

Planetary Spider Assembly Tool ..................................................................................................................61

Toric Ring Face Seal Assembly Tool ............................................................................................................61

Notes

Asbestos and Non-Asbestos Fibers

!

ASBESTOS FIBER WARNING

The following procedures for servicing brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung disease hazard. Material

Safety Data Sheets are available from AxleTech.

Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must understand the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma

(a cancer of the lining of the chest or abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more years after the first exposure to asbestos.

Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to asbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to areas where exposures exceed either of the maximum allowable levels:

DANGER: ASBESTOS

CANCER AND LUNG DISEASE HAZARD

AUTHORIZED PERSONNEL ONLY

RESPIRATORS AND PROTECTIVE CLOTHING

ARE REQUIRED IN THIS AREA

2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning with the removal of the wheels.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed.

Wipe the brake parts clean with a cloth.

c. If an enclosed vacuum system or brake washing equipment is not available, employers may adopt their own written procedures for servicing brakes, provided that the exposure levels associated with the employer’s procedures do not exceed the levels associated with the enclosed vacuum system or brake washing equipment. Consult

OSHA regulations for more details.

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter.

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a

HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.

5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not shake or use compressed air to remove dust from work clothes.

6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United

States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.

!

NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to non-asbestos fiber dust, a potential cancer and lung disease hazard. Material Safety Data Sheets are available from AxleTech.

Hazard Summary

Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.

Scientists disagree on the extent of the risks from exposure to these substances.

Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.

Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing difficulty. Some scientists believe other types of non-asbestos fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and international agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential causes of cancer.

Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to nonasbestos dust follow. Consult your employer for more details.

- 1 -

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other operations to reduce risks to unprotected persons.

2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 mg/m 3 as an 8-hour time-weighted average. Some manufacturers of nonasbestos brake linings recommend that exposures to other ingredients found in nonasbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.

Scientists disagree, however, to what extent adherence to these maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling nonasbestos dust.

Therefore, wear respiratory protection at all times during brake servicing, beginning with the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or manufacturer’s recommended maximum levels. Even when exposures are expected to be within the maximum allowable levels, wearing such a respirator at all times during brake servicing will help minimize exposure.

3. Procedures for Servicing Brakes.

a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts. The solution should be applied with low pressure to prevent dust from becoming airborne. Allow the solution to flow between the brake drum and the brake support or the brake rotor and caliper. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.

c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean the brake parts in the open air. Wet the parts with a solution applied with a pump-spray bottle that creates a fine mist. Use a solution containing water, and, if available, a biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly components should be thoroughly wetted to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts clean with a cloth.

d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or machining brake linings. In addition, do such work in an area with a local exhaust ventilation system equipped with a HEPA filter.

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a

HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, flammable solvents, or solvents that can damage brake components as wetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.

When you empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care.

5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.

Do not shake or use compressed air to remove dust from work clothes.

6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste disposal.

Regulatory Guidance

References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the

United States, are made to provide further guidance to employers and workers employed within the United States. Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance.

Section 1

Exploded View

PRC 485Q (with Q Plus™ Cam Brakes)

2

3

4

5

6

13

1

9

8

10

11

7

19

24

23

26

27

20

21

22

23

25

28

29

31

12

30

17

14

15

16

18

32

ITEM DESCRIPTION

1 Spindle

2 Flat Washer

3 Cap Screw

4 Wear Sleeve

5 Oil Seal Assembly

6 Inner Bearing Cone

7 Inner Bearing Cup

8 O-Ring

9 Hub

10 Outer Bearing Cup

11 Outer Bearing Cone


12 Machine Screw

13 Wheel Stud

14 Ring Gear Hub

15 Spindle Nut

16 Set Screw

17 Sun Gear Thrust Washer

18 Planetary Sun Gear

19 Snap Ring

20 Lock Ring

21 Ring Gear

22 Pinion Shaft

- 2 -


23 Needle Rollers

24 Spacer

25 Planetary Pinion Gear

26 Thrust Washer

27 Thrust Button

28 O-Ring

29 Planetary Spider

30 Magnetic Drain Plug

31 Spiral Retaining Ring

32 Brake Drum

Section 1

Exploded View

PRC 485 W3H

2

3

4

5

6

7

8

1

10

9

11

12

14

15

16

20

17


1 Spindle

2 Flat Washer

3 Cap Screw

4 Wear Sleeve

5 TRS Face Seal Assembly

6 Oil Seal Assembly


8 Inner Bearing Cup

9 O-Ring

10 Hub


18

19

21

25

22

23

24

24 26

27

29

28

30



13 Machine Screw

14 Wheel Stud

15 Ring Gear Hub

16 Spindle Nut

17 Set Screw



20 Snap Ring

21 Lock Ring

22 Ring Gear

- 3 -

13

31

32


23 Pinion Shaft

24 Needle Rollers

25 Spacer


27 Thrust Washer

28 Thrust Button

29 O-Ring

30 Planetary Spider



Section 1

Exploded View

PRC 785P

2

3

4

5

6

1

7

13

9

8

10

11

14

15

16

18

19

17

20

21

23

22

23

24 25

26

28

27

29

30

31

12

32


1 Spindle

2 Flat Washer

3 Cap Screw

4 Wear Sleeve

5 Oil Seal Assembly


7 Inner Bearing Cup

8

9

O-Ring

Hub




12 Machine Screw

13 Wheel Stud

14 Ring Gear Hub

15 Spindle Nut


17 Set Screw


19 Snap Ring

20 Lock Ring

21 Ring Gear

22 Pinion Shaft

- 4 -


23 Needle Rollers

24 Spacer


26 Thrust Washer

27 Thrust Button

28 O-Ring

29 Planetary Spider



32 Brake Drum

Section 1

Exploded View

PRC 785 W3H

2

3

4

5

6

7

8

1

10

14

15

16

17

9

11

12

20


1 Spindle

2 Flat Washer

3 Cap Screw

4 Wear Sleeve

5 TRS Face Seal Assembly

6 Oil Seal Assembly


8 Inner Bearing Cup

9 O-Ring

10 Hub


18

19

21

22

25

23

24

26

27

29

28



13 Machine Screw

14 Wheel Stud

15 Ring Gear Hub

16 Spindle Nut

17 Set Screw



20 Snap Ring

21 Lock Ring

22 Ring Gear

- 5 -

13

32

30

31


23 Pinion Shaft

24 Needle Rollers

25 Spacer


27 Thrust Washer

28 Thrust Button

29 O-Ring

30 Planetary Spider



Section 2

Introduction

Description

[Figure 2.1] AxleTech’s PRC 485Q (with Q Plus™ cam brakes) and PRC 785P planetary axles incorporate a single reduction carrier/differential assembly with hypoid gearing. They are equipped with the RS-145 carrier series. The final reduction is of planetary spur designed gearing built into the wheel hubs. The axles have only cast housings.

Figure 2.1

•

The teeth of the floating sun gear mesh with the teeth of the planetary spur gears.

•

The planetary gears rotate on planetary shafts that are mounted on a spider. The planetary gear teeth in turn mesh with the teeth of the floating ring gear.

•

The hypoid gear set in the carrier transmits power to the axle shafts and the sun gear of the final reduction, through the revolving planetary gears, and into the planetary spider.

•

The planetary wheel ends on both the PRC 485 and 785 are serviced almost identically for cam or wet disc brakes.

PRC 485Q (with Q PLUS™ CAM BRAKES)

AxleTech planetary axles permit the hypoid gearing of the carrier and the axle shafts to carry only a nominal torsional load. At the same time, they provide the highest practical numerical gear reduction at the wheels.

•

The hypoid pinion and differential assembly of the first reduction is supported by tappered roller bearings.

•

A hardened precision spacer between the inner and outer pinion bearings adjusts and maintains the pinion bearing preload.

•

The positioning of the threaded adjusting rings in the carrier leg and cap bores adjusts and maintains the differential tapered bearing preload and sets ring & pinion backlash.

- 6 -

Section 2

Introduction

Identification

[Figure 2.2] The exact axle model specification is shown on the identification tag located on the axle housing.

Figure 2.2

SINGLE PLANETARY AXLES

P –

PLANETARY

R –

RIGID

ONLY IF APPLICABLE:

L –

MOUNTING OTHER THAN PAD

WITH DRILLING

HOUSING TYPE

DESIGNATION:

C –

INTEGRAL CAST

P R __ C 7 8 5 P 100

FIRST TWO OR

THREE DIGITS:

WHEEL END

DESIGNATION

(BASIC MODEL

NUMBER)

LAST DIGIT:

CARRIER

DESIGNATION

FOR BASE MODEL

NUMBER

BRAKE TYPE:

N

P

Q

W3H

— NONE

— CAM-MASTER

®

— CAM-MASTER

®

— DURA-DISC

®

“P” SERIES CAM

“Q” SERIES

14.2 in. (360 mm) WET DISC

EXACT

SPECIFICATION

- 7 -

Section 3

Disassembly

PRC 485Q (with Q Plus™ Cam Brakes) Wheel End Cross Section

AXLE

SHAFT

OIL SEAL

INNER

BEARING

WHEEL

STUD

OUTER

BEARING

RING

GEAR

HUB

SET

SCREW

SPACER

PLANET

GEAR

SPINDLE

NUT

SPIRAL

RETAINING

RING

O-RING

PLANETARY

PINION

SHAFT

THRUST

BUTTON

SUN

GEAR

NEEDLE

ROLLERS

SPINDLE

WEAR

SLEEVE

BRAKE

DRUM

WHEEL

HUB

O-RING

MACHINE

SCREW

SUN GEAR

THRUST

WASHER

LOCK RING

RING

GEAR

PLANETARY

SPIDER

MAGNETIC

DRAIN

PLUG

!

WARNING

To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.

PRC 485Q (with Q Plus™ Cam

Brakes) Planetary Axle

Wheel End

!

WARNING

Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands.

Do not work under a vehicle that is supported only by jacks. Jacks can slip or fall over. Serious personal injury can result.

Brake Drum

1. Make sure 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 that the wheels of the axle to be serviced are off the ground. Support the vehicle with safety stands. Refer to the vehicle maintenance manual for instructions on raising the vehicle.

4. Remove the wheel nuts and dual tire/rim assemblies from both wheel ends.

5. Rotate the wheel ends so the magnetic drain plug in the planetary spider is at the bottom. Remove the plug. Drain and discard the lubricant from both wheel ends.

- 8 -

Section 3

Disassembly

6. If necessary, remove the magnetic drain plug from the bottom of the axle housing. Drain and discard the lubricant from the carrier center section.

!

WARNING

When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury.

7. If the brake air chamber assembly has a spring chamber unit, carefully cage and lock the spring to prevent the spring from activating during disassembly.

NOTE:

If Meritor automatic slack adjusters are used, refer to Maintenance Manual 4, Automatic Slack

Adjuster for the correct adjustment procedure. To order this publication, call ArvinMeritor’s Customer

Service Center at 800-535-5560.

8. Adjust the brake slack adjuster to retract the brake shoes to produce clearance between the lining and the brake drum.

!

WARNING

To prevent serious personal injury and possible damage to components, be very careful when using lifting devices during service and maintenance procedures.

•

Inspect to make sure that neither lifting strap is damaged.

•

Do not subject lifting straps to any shock or drop loading.

9. [Figure 3.1] Use a lifting device to support the brake drum.

Figure 3.1

10. Install capscrews into the threaded holes in the brake drum. Gradually tighten the capscrews in equal amounts to push the drum off the pilot surface of the planetary spider.

- 9 -

Section 3

Disassembly

11. [Figure 3.1] With the lifting device, carefully remove the brake drum.

Planetary Spider Assembly

!

WARNING


•


•


1. Remove the 3 slotted head machine screws that attach the planetary spider to the hub.

2. With a lifting device, remove the planetary spider assembly from the wheel hub and set it on a workbench. Rest the spider with the large flange ending up.

3. Mark the large ends of the planetary pinion shafts and the planetary spider to aid in reassembly if the original pinion shafts are used.

4. [Figure 3.2] Place the planetary spider assembly on blocks with the large flange end facing DOWN.

Remove the spiral retaining ring by lifting exposed ring end with a screw driver and spiraling ring out from slot in pins. If removal is not possible, the spiral retaining ring may be cut into sections.

Figure 3.2

!

WARNING

Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury.

Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.

!

CAUTION

To avoid damage to the pinion shaft, provide a soft cushioned area to receive the pinion shaft when it is removed from the spider.

5. Use a press to remove the pinion shafts out of the spider. If a press is not available, use a brass drift and mallet to drive out the shaft.

Press or drive the pinion shaft out toward the large flange end of the spider which faces

DOWN.

6. Remove the planetary pinions and the thrust washer from the planetary spider.

7. Remove axle-shaft thrust button only if it’s worn.

8. Remove the axle shaft, planetary sun gear and snap ring assembly.

NOTE:

The sun gear thrust washer may come out with the axle shaft and sun gear assembly.

9. Remove the sun gear thrust washer from the axle shaft or if necessary remove the sun gear thrust washer from the end of the spindle.

10. Remove the snap ring from the axle shaft to allow for the removal of the sun gear from the axle shaft.

11. Remove the lock ring.

12. Remove the ring gear.

- 10 -

Section 3

Disassembly

13. Remove the set screw from the spindle nut.

14. Remove the spindle nut.

15. Remove the planetary ring gear hub. The outer wheel bearing cone will remain on the ring gear hub. If it is damaged, remove it from the hub.

16. Remove the wheel hub. The hub oil seal and inner bearing assembly will remain in the hub.

!

CAUTION

Do not damage the hub oil seal bore surface in the wheel hub. Damage to this surface will result in oil leakage after assembly.

17. Remove the hub oil seal.

18. Remove the inner bearing cone.

19. If replacement of the wheel bearings is necessary, press out the outer bearing cup and inner bearing cup.

20. Remove and discard the O-ring from the wheel hub.

Cam Brakes

To disassemble the PRC 485Q (with Q Plus™ cam brakes), refer to Maintenance Manual No. 4, Cam

Brakes. To order this publication, call ArvinMeritor’s

Customer Service Center at

800-535-5560.

If it is necessary to remove the anchor pins, remove the brake dust shields for convenient access to the anchor pins.

Spindle and Brake Spider

!

WARNING


•


•

Do not subject lifting loops or lifting straps to any shock or drop loading.

Removal of the capscrews allows the spindle and brake assembly to separate. They can fall from the planetary axle housing and cause damage to components and serious personal injury.

1. To prevent the spindle and the brake spider from falling after all the mounting capscrews are removed, use one of the following procedures:

A. Use a lifting device to support the spindle during disassembly.

B. [Figure 3.3] Remove only two capscrews.

Replace them with two temporary M16 x 2.0

thread studs four inches (102 mm) long before the remaining capscrews are removed.

•

Install one stud at the eleven o’clock position.

•

Install one stud at the one o’clock position.

Figure 3.3

- 11 -

Section 3

Disassembly

2. Remove the two capscrews and washers that mount the clamp around the brake camshaft housing tube to the axle housing.

3. Remove the capscrews and washers that mount the brake spider and spindle to the axle housing.

4. Remove the brake spider and air chamber assembly from the spindle.

5. Remove the spindle from the axle housing. If necessary, tap lightly on the spindle to loosen the pilot fit and to overcome the adhesion due to the cured gasket material in the flange joint.

6. Inspect the wear sleeve for damage and wear and remove it as necessary using heat.

- 12 -

Section 3

Disassembly


FACE SEAL

OIL SEAL

AXLE SHAFT

SPINDLE

WEAR

SLEEVE

WET BRAKE

PISTON HOUSING

INNER

BEARING

WHEEL

STUD

OUTER

BEARING

LOCK

RING

RING GEAR

HUB

SPACER

NEEDLE

ROLLERS

O-RING

SET SCREW

SUN GEAR

THRUST

WASHER

WET BRAKE

DISC HOUSING

WHEEL HUB

MACHINE

SCREW

O-RING

SPINDLE

NUT

PLANETARY

SPIDER

RING

GEAR

SUN GEAR

THRUST

BUTTON

PLANETARY

PINION SHAFT

SPIRAL RETAINING RING

MAGNETIC

DRAIN PLUG

PLANETARY

GEAR


Wheel End

!

WARNING



Preliminary Disassembly







- 13 -

Section 3

Disassembly


!

WARNING


•


•







Figure 3.4

!

WARNING



!

CAUTION




DOWN.




NOTE:










!

CAUTION


- 14 -





Section 3

Disassembly

Wheel End

Refer to Maintenance Manual MM-20195, Wet

Disc Brake with Dowel Pins/Model W3H (360 mm).

Call AxleTech’s Customer Service Center at

877-547-3407 to order this publication.

You can also access maintenance and product information on AxleTech’s web site. Refer to the

Service Notes page on the front inside cover of this manual for instructions on how to access the site.

!

CAUTION

Care should be taken to store the (2) halves of the face seal to protect them from damage and saved for reassembly later when required.

1. Remove the half TRS face seal from the hub.

2. Remove the remaining half of the face seal from the brake disc assembly.

NOTE:

Place the face seals together and store in a safe package to prevent damage.

!

WARNING


3. Loosen sixteen M16 x 1.5 threaded capscrews.

Hit the threaded capscrew heads with a mallet to separate the wet disc brake housing.

4. Remove all but two capscrews at the eleven o’clock and one o’clock positions.

!

CAUTION

Do not reuse a damaged friction disc or stationary disc. Damage to components can result.

The friction discs and stationary discs are loose inside the brake housing assembly. Reach through the center of the brake housing and keep the discs from falling out.

5. Support the brake housing assembly. Remove the remaining capscrews.

6. Remove the brake housing assembly from the piston housing and set it on a table with the discs facing up to prevent the discs from falling out.

7. Remove the four shoulder bolts from the piston and piston housing.

8. Remove the washers and springs from the four shoulder bolts. Push the piston from the piston housing. Use less than 20 psi (1.38 bar) air pressure. Insert three adjuster screws. Evenly turn the screws CLOCKWISE.

Spindle and Piston Housing

!

WARNING


•


•


Removal of the capscrews allows the spindle and piston housing to separate. They can fall from the planetary axle housing and cause damage to components and serious personal injury.

1. To prevent the spindle and piston housing from falling after all the mounting capscrews are removed, perform the following procedures:


- 15 -

Section 3

Disassembly

B. Remove only two capscrews. Replace them with two temporary M20 x 2.5 thread studs four inches (102 mm) long before the remaining capscrews are removed.

•


•


2. Remove the capscrews and washers that secure the piston housing and spindle to the axle housing.

3. Remove the piston housing from the spindle.

4. [Figure 3.5] Remove the spindle from the axle housing. If necessary, tap lightly on the spindle to loosen the pilot fit and to overcome the adhesion due to the cured gasket material in the flange joint.

Figure 3.5

Wet Disc Brakes








- 16 -

Section 3

Disassembly

PRC 785P Wheel End Cross Section

SPINDLE

AXLE SHAFT

BRAKE DRUM

WEAR

SLEEVE

OIL SEAL

INNER

BEARING

OUTER

BEARING

WHEEL

HUB

O-RING

WHEEL

STUD

MACHINE

SCREW

SPACER

NEEDLE

ROLLERS

RING

GEAR

HUB

SPINDLE

NUT

LOCK RING

RING GEAR

SET

SCREW

SUN GEAR

THRUST

WASHER

SPIRAL

RETAINING

RING

PLANETARY

SPIDER

SUN GEAR

THRUST

BUTTON

PLANETARY

PINION

SHAFT

O-RING

PLANETARY

GEAR

MAGNETIC

DRAIN

PLUG


Wheel End

!

WARNING



Brake Drum






- 17 -

Section 3

Disassembly


!

WARNING

When you work on a spring chamber, carefully follow the service instructions of the chamber manufacturer. Sudden release of a compressed spring can cause serious personal injury.

7. If the brake air chamber assembly has a spring chamber unit, carefully cage and lock the spring to prevent the spring from activating during disassembly.

NOTE:

If Meritor automatic slack adjusters are used, refer to Maintenance Manual 4, Automatic Slack

Adjuster, for the correct adjustment procedure. To order this publication, call ArvinMeritor’s Customer

Service Center at 800-535-5560.

8. Adjust the brake slack adjuster to retract the brake shoes to produce clearance between the lining and the brake drum.

!

WARNING


•


•


9. [Figure 3.6] Use a lifting device to support the brake drum.

Figure 3.6

10. Install capscrews into the threaded holes in the brake drum. Gradually tighten the capscrews in equal amounts to push the drum off the pilot surface of the planetary spider.

11. With the lifting device, carefully remove the brake drum.

- 18 -

Section 3

Disassembly


!

WARNING


•


•







Figure 3.7

!

WARNING



!

CAUTION




DOWN.




NOTE:










- 19 -

!

CAUTION






Section 3

Disassembly

Cam Brakes

To disassemble the P Series brake, refer to

Maintenance Manual 4, Cam Brakes. To order this publication, call ArvinMeritor’s Customer Service

Center at 800-535-5560.

If it is necessary to remove the anchor pins, remove the brake dust shields for convenient access to the anchor pins.

Spindle and Brake Spider

!

WARNING


•


•


!

WARNING

Removal of the capscrews allows the spindle and brake assembly to separate. They can fall from the planetary axle housing and cause damage to components and serious personal injury.

1. To prevent the spindle and brake spider from falling after all the mounting capscrews are removed, use one of the following procedures:


B. [Figure 3.8] Remove only two capscrews.

Replace them with two temporary M20 x 2.5

UNC thread studs four inches (102 mm) long before the remaining capscrews are removed.

•


•


Figure 3.8

2. Remove the two capscrews and washers that mount the clamp around the brake camshaft housing tube to the axle housing.

3. Remove the capscrews and washers that secure the brake spider and spindle to the axle housing.

4. Remove the brake spider and air chamber assembly from the spindle.

5. Remove the spindle from the axle housing. If necessary, tap lightly on the spindle to loosen the pilot fit and to overcome the adhesion due to the cured gasket material in the flange joint.


- 20 -

Section 3

Disassembly


FACE SEAL

INNER

BEARING

OUTER

BEARING

LOCK

RING

OIL SEAL

AXLE SHAFT

SPINDLE

SET SCREW

SPINDLE

NUT

SUN GEAR

THRUST

WASHER

SUN GEAR

THRUST

BUTTON

SPACER

PLANETARY

PINION SHAFT

SPIRAL

RETAINING RING

O-RING

MAGNETIC

DRAIN PLUG

WEAR SLEEVE

WET BRAKE

PISTON HOUSING WET BRAKE

DISC HOUSING

O-RING

WHEEL

HUB

WHEEL

STUD

MACHINE SCREW

RING

GEAR

PLANETARY

SPIDER

NEEDLE

ROLLERS

RING

GEAR

HUB

PLANETARY

GEAR


Wheel End

!

WARNING



Preliminary Disassembly







- 21 -

Section 3

Disassembly


!

WARNING


•


•







Figure 3.9

!

WARNING



!

CAUTION




DOWN.




NOTE:










- 22 -

!

CAUTION






Section 3

Disassembly

Wheel End







!

CAUTION

Care should be taken to store the (2) halves of the face seal to protect them from damage and saved for reassembly later when required.

1. Remove the half TRS face seal from the hub.

2. Remove the remaining half of the face seal from the brake disc assembly.

NOTE:

Place the face seals together and store in a safe package to prevent damage.

!

WARNING


3. Loosen sixteen M16 x 1.5 threaded capscrews.

Hit the threaded capscrew heads with a mallet to separate the wet disc brake housing.

4. Remove all but two capscrews at eleven o’clock and one o’clock positions.

!

CAUTION



5. Support the brake housing assembly. Remove the remaining capscrews.

6. Remove the brake housing assembly from the piston housing and set it on a table with the discs facing up to prevent the discs from falling out.

7. Remove the four shoulder bolts from the piston and piston housing.

8. Remove the washers and springs from the four shoulder bolts. Push the piston from the piston housing. Use less than 20 psi (1.38 bar) air pressure. Insert three adjuster screws. Evenly turn the screws CLOCKWISE.

Spindle and Piston Housing

!

WARNING


•


•


Removal of the capscrews allows the spindle and piston housing to separate. They can fall from the planetary axle housing and cause damage to components and serious personal injury.

1. To prevent the spindle and piston housing from falling after all the mounting capscrews are removed, perform the following procedures:


- 23 -

Section 3

Disassembly

B. Remove only two capscrews. Replace them with two temporary M20 x 2.5 thread studs four inches (102 mm) long before the remaining capscrews are removed.

•


•


2. Remove the capscrews and washers that secure the piston housing and spindle to the axle housing.

3. Remove the piston housing from the spindle.

4. [Figure 3.10] Remove the spindle from the axle housing. If necessary, tap lightly on the spindle to loosen the pilot fit and to overcome the adhesion due to the cured gasket material in the flange joint.

Figure 3.10

Wet Disc Brakes








- 24 -

Section 4

Prepare Parts for Assembly

!

WARNING


Clean Ground or Polished

Parts

!

WARNING

Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-based cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s product instructions and these procedures:

•

Wear safe eye protection.

•

Wear clothing that protects your skin.

•

Work in a well-ventilated area.

•

Do not use gasoline or solvents that contain gasoline. Gasoline can explode.

•

You must use hot solution tanks or alkaline solutions correctly. Follow the manufacturer’s instructions carefully.

!

CAUTION

•

Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or water and alkaline solutions will damage these parts.

Isopropyl alcohol, kerosene or diesel fuel can be used for this purpose.

•

If required, use a sharp knife to remove gasket material from parts. Be careful not to damage the ground or polished surfaces.

1. Use a cleaning solvent, kerosene or diesel fuel, to clean ground or polished parts or surfaces.

NEVER USE GASOLINE.

2. Remove gasket material from parts. Take care not to damage ground surfaces.

3. DO NOT clean ground or polished parts in a hot solution tank, water, steam or alkaline solution.

Clean Parts with a

Rough Finish

1. Use a cleaning solvent or a hot solution tank with a weak alkaline solution to clean parts with a rough finish.

2. Leave parts in the hot solution tank until they are completely cleaned and heated. When the parts are clean, remove them from the tank.

3. Wash the parts with water until you completely remove the alkaline solution.

Clean Axle Assemblies

•

A complete axle assembly can be steam cleaned on the outside to remove dirt.

•

Before the axle is steam cleaned, close or put a cover over all the openings in the axle assembly.

Examples of openings are the breathers or vents in air chambers.

!

CAUTION

Dry bearings with clean paper or rags. Do not use compressed air, which can cause abrasive particles to contaminate the bearings. Damage to components and reduced lining life can result.

Dry Cleaned Parts

•

Immediately after cleaning, use clean paper, rags or compressed air to dry parts.

Prevent Corrosion

NOTE:

Parts must be clean and dry before you lubricate them.

1. If you assemble the parts immediately after

you clean them:

Lubricate the clean, dry parts with grease to prevent corrosion.

2. If you store the parts after you clean them:

Apply a corrosion-preventive material to all machined surfaces. Store the parts in a special paper or other material that prevents corrosion.

- 25 -

Section 4


Inspect Parts

•

It is important to carefully inspect all parts for wear and damage before you assemble the axle carrier.

•

Replace damaged parts.

Inspect Tapered Roller Bearings

Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. If any of the following conditions exist, replace the bearing:

•

The centers of the large diameter end of the rollers are worn level with or below the surface.

•

[Figure 4.1]

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

•

[Figure 4.2]

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

Figure 4.2

CRACK WEAR GROOVES

Figure 4.1

WORN RADIUS

WORN SURFACE

- 26 -

Section 4


•

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

•

[Figure 4.3]

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

Figure 4.3

•

[Figure 4.5]

Spalling or flaking is present on the cup and cone inner race surfaces that touch the rollers.

Figure 4.5

SPALLING AND

FLAKING

WEAR MARKS

•

[Figure 4.4]

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

Figure 4.4

ETCHING AND

PITTING

Inspect the Bevel Pinion and Ring

Gear Sets

!

CAUTION

The bevel drive pinions and ring gears are machined in matched sets. When a drive pinion or ring gear of a bevel set needs to be replaced, both drive gear and pinion must be replaced at the same time. A higher stress on the original parts and early failure of the entire assembly will result if a new part is used in combination with parts that are older or worn.

wear and damage. Gears that are worn or damaged must be replaced.

- 27 -

Section 4


Inspect the Main Differential

Assembly

1. Use a cleaning solvent, kerosene or diesel fuel, to clean the interior of the main differential assembly. NEVER USE GASOLINE.

2. Use the left shaft to rotate one side gear. Replace the differential assembly if you see any binding.

3. Observe the side gear and differential pinions during rotation. Replace the differential assembly if you see chipped or broken teeth, or if there are damaged cases.

Inspect the Axle Shafts

If there is any wear or cracks at the flange, shaft and splines, replace the axle shaft.

Inspect the Yoke

If there is excessive wear at the seal journal area, replace the yoke.

Inspect the Brakes







Repair or Replace Parts

Replace the worn or damaged parts of an axle assembly. The following are some examples to check for repair and possible replacement:

•

Replace any fastener if corners of the head are worn.

•

Replace washers if damaged.

•

Replace gaskets, oil seals or grease seals at the time of axle repair.

•

Clean parts and apply new liquid gasket material where required when the axle is assembled.

•

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

•

Clean and repair the threads of fasteners and holes. Use a die or tap of the correct size or a fine file for this purpose.

•

Tighten all fasteners to the correct torque values.

Refer to chart in Section 6 for fastener torque values.

T

Repair Welding

!

WARNING

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.

Inspect the axle components. Replace if damaged or worn. Do not weld repair or recondition.

- 28 -

Section 4


Apply Silicone Gasket Material

(All Specs Spindle To Housing

Joint)

AxleTech Specifications:

•

ThreeBond 1216

•

Loctite 5699

!

WARNING

When you apply 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.

1. Remove all the old gasket material from the surfaces of both components.

2. Clean the surfaces where the liquid gasket material will be applied. Remove all the oil, grease, dirt and moisture.

3. Thoroughly dry both surfaces.

!

CAUTION

The amount of liquid gasket material applied to component surface must not exceed 0.125 inch

(3.18 mm) diameter bead. Too much gasket material can block lubrication passages. Damage to components can result.

4. [Figure 4.6] Apply a 0.125 inch (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.

Figure 4.6

0.125" (3.18 MM)

DIAMETER SILICONE

GASKET MATERIAL BEAD

5. Assemble the components immediately to permit the gasket material to compress evenly between parts.

Tighten the fasteners to the required torque value for that size fastener using an “X” torquing pattern.

Refer to the Torque Chart in Section 6.

6. Wait 20 minutes before filling the assembly with lubricant.

- 29 -

Section 5

Assembly

!

WARNING


PRC 485Q (with Q Plus™ Cam

Brakes) Planetary Axle

Wheel End


NOTE:

Refer to Section 4, “Prepare Parts for

Assembly.”

Spindle, Brake Spider and Brake

1. [Figure 5.1] Install two temporary studs

(M16 - 2.0 threads, approximately four inches long) into the axle housing flange. Install the studs at the eleven o’clock and one o’clock positions.

Figure 5.1

!

WARNING

When you apply 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.

3. [Figure 5.2] Apply a 0.125 inch (3.18 mm) diameter continuous bead of silicone gasket material around the flange mounting face of either the axle housing or the spindle. Also apply the gasket material around the edge of all the fastener holes on that surface.

Figure 5.2

GASKET

MATERIAL

2. If wear sleeve was removed, reinstall by applying

Loctite 518 to the wear sleeve ID and press it onto the spindle using driver tool 0978530003.

4. Install the spindle onto the axle housing.

5. Install the brake spider onto the spindle.

6. Install and hand tighten some of the spindle mounting capscrews and washers.

7. Remove the two temporary studs.

8. Install the remaining spindle mounting capscrews and washers. Tighten all capscrews to 200-260 lbft (270-350 N•m).

- 30 -

Section 5

Assembly

NOTE:

Replace the camshaft bushing and grease seals before the camshaft bracket is installed onto the brake spider. Refer to Maintenance Manual 4,

Cam Brakes. To order this publication, call

ArvinMeritor’s Customer Service Center at 800-535-5560.

9. Install the brake camshaft bracket with the

O-ring on the pilot onto the brake spider.

10. Install the four mounting capscrews and washers. See "Torque Table" in section 6.

NOTE:

Refer to Maintenance Manual 4, Cam

Brakes; and Automatic Slack Adjuster, to install the brake camshaft, anchor pin components, brake shoes, brake springs, slack adjusters and related parts. To order this publication, call ArvinMeritor’s

Customer Service Center at 800-535-5560.

11. Install the brake camshaft bracket clamp around the bracket tube. Install the two capscrews and washers that mount the clamp to the axle housing. See "Torque Table" in section 6.

12. Install the air chamber-to-bracket mounting nuts. See "Torque Table" in section 6.

13. Attach the chamber push rod yoke to the slack adjuster. See "Torque Table" in section 6.

14. Install the brake dust shield. Tighten the mounting capscrews and washers. See

"Torque Table" in section 6.

Wheel End

1. Press the new inner and outer bearing cups into the wheel hub using 0979541000 and

0979540000 tool drivers.

2. Position the wheel hub with the oil seal bore facing UP.

3. Apply axle gear lubricant to the bearing rollers and install the inner wheel bearing cone.

!

CAUTION

•


NOTE:

Use a Permatex coating to seal against leaks around the hub oil seal. Leaks would result in requiring disassembly, should leak be noted after the final axle assembly.

4. Apply a light, uniform coating of Permatex to the wheel hub bore.

5. [Figure 5.3] Use the oil seal driver 0979542000 to install the wheel hub oil seal. See figure for proper seal orientation. Press the seal into the hub until the seal face is flush with the hub face.

Figure 5.3

6. Apply a light film of axle lubricant to the hub oil seal rubber lips and wear sleeve contact surface and lead in chamfer.

7. Install the wheel hub, inner bearing and oil seal assembly onto the spindle. Keep the hub assembly aligned with the spindle.

- 31 -

Section 5

Assembly

8. Apply axle lubricant to the outer bearing cone rollers. Install the outer bearing cone onto the ring gear hub.

9. Install the planetary ring gear onto the ring gear hub with lock ring.

10. Install ring gear hub/ring gear onto spindle.

11. Install the wheel bearing adjusting nut.

Adjust the Wheel Bearing Preload

NOTE:

To adjust the wheel bearing preload, the bearings must be seated and the rollers in proper alignment.

!

WARNING


1. Install the wheel bearing adjusting nut. See


2. Rotate the hub in both directions. At the same time, tap the hub several times with a brass or plastic mallet.

3. Tighten the nut using the spindle nut tool

0979534000. Tighten further until one of the nut’s scallops lines-up with one of the threaded holes in the ring hub. See special tool section. See


4. Back off the nut approximately 1/4 turn to relieve the preload produced in Step 3.

5. Install the set screw.

6. Tighten the set screw. See "Torque Table" in section 6.

7. Apply a thin layer of axle grease to the face of the sun gear thrust washer.

8. Install the sun gear thrust washer. The washer tangs must engage the slots in the spindle nut.

9. Install the planetary sun gear and snap ring onto the axle shaft.

10. Install the axle shaft and sun gear assembly. For correct installation:

•

The axle shaft must make engagement with the differential side gear.

•

The sun gear must make contact with the thrust washer.

•

Insure washer tangs are keyed into the spindle nut slots.

11. Install the O-ring on the wheel hub at the base of the flange.

Planetary Spider and

Gearing Assembly

!

WARNING

When you apply 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.

1. Apply adhesive material to the axle shaft thrust button shaft before placing it into the spider.

2. Ensure no adhesive will touch the O-ring or the internal surface of the spider holes.

- 32 -

Section 5

Assembly

3. Make the planet gear subassemblies.

A. Put a planet shaft standing with the big shoulder flange down.

B. Apply gear lubricant.

C. Assemble on the planet shaft shoulder 33 needle rollers.

D. Insert the planet gear on the planet shaft such as the rollers end up between the planet shaft

OD and planet gear ID with the grooved face of planet gear down against shaft flange.

E. Insert a spacer on top of the 1st set of 33 needle rollers.

F. Add the 2nd set of 33 needle rollers.

4. Install the planet gears subassemblies into the planet spider assembly tool 0979600000. See special tool section 7, Figure 7.2.

5. Install the big thrust washer.

6. Install the corresponding O-rings into each planet gears subassembly.

7. Align the spider with the planet gears subassemblies and with the flange down.

8. Press the spider into the planet gears subassemblies until the planet gears subassemblies are flush with the end of the spider.

9. [Figure 5.4] Install the spiral retaining ring by feeding one end of the ring into the slots in the planet pins.

Figure 5.4

Final Assembly

NOTE:

For correct installation, the planetary pinions must engage both the sun gear and the ring gear before installation.

1. Install the planetary spider and gearing assembly onto the wheel hub.

2. Install the three slotted head machine screws that attach the planetary spider to the wheel hub.

Tighten the screws, compressing o-ring until no gap exists between wheel hub flange and spider flange.

3. Install the brake drum over the wheel studs until the drum seats onto the planetary spider flange.

4. Mount the inner and outer wheels. Install the wheel nuts and tighten them to the vehicle manufacturer’s specification.

NOTE:

The PRC 485Q (with Q Plus™ Cam Brakes) axle has a common oil level between the carrier and the wheel ends. Three locations must be filled. The vehicle must be on a level surface when filling. Fill to the bottom of each fill plughole. Wait and allow the oil to flow through the axle. Check the oil level again after several minutes and fill to the specified level if necessary.

5. Add the correct axle lubricant into each wheel end through the fill/level hole in the planetary spider at the horizontal position (3 or 9 o’clock).

6. Add the correct lubricant to the axle housing bowl area.

7. Apply sealant to the threads of the fill/level plugs.

8. Install the fill/level plugs and tighten to 35 lb-ft

(47 N•m).

- 33 -

Section 5

Assembly


Wheel End


NOTE:


Assembly.”

Spindle and Piston Housing to the Axle Housing

1. [Figure 5.5] Install two temporary studs (M20 x

2.5 threads, approximately four inches long) into the axle housing flange. Install the studs at the eleven o’clock and one o’clock positions.

Figure 5.5



!

WARNING

Take care when using Loctite ® to avoid serious personal injury. Follow the manufacturer’s instructions to prevent irritation to the eyes and skin. If Loctite gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a doctor as soon as possible.

NOTE:

The piston housing has TOP identified by a raised lug.

3. Clean and inspect the spindle and piston housing for damage. Apply a small, two millimeter bead of

Q48 (Loctite 518) near the OD of the spindle flange and around each bolt hole, on both sides of the spindle flange.

4. Mount the spindle and piston housing (lug on

TOP) onto the axle housing using thirteen

M20 x 2.5 thread capscrews. Tighten the capscrews in an “X” torquing pattern to achieve

370-480 lb-ft (500-650 N•m) bolt torque.

5. Install 10 mm x 60 mm long assembly studs into the four M8 x 1.25 thread holes in the piston cover.

Wet Disc Brakes

To assemble the PRC 485 W3H wet disc brakes, refer to Maintenance Manual MM-20195, 360 mm

Wet Disc Brakes. To order this publication, call

AxleTech International Customer Service Center at

877-547-3907.

NOTE:

To continue assembling the PRC 485 W3H wet disc brake wheel end, continue with the following steps.

- 34 -

Section 5

Assembly

Wheel End

1. Clean and inspect the piston for damage, inspect the piston grooves to ensure no contaminants remain in the grooves.

2. Apply an oil lubricant to the “D” seals and assemble the “D” seals into the appropriate grooves in the piston.

!

WARNING


3. Apply an oil film coating on the piston housing bores. Use “C” clamps to assemble the piston over the assembly studs and push the piston into the piston housing until it bottoms out.

NOTE:

The piston slightly sticks out of the piston housing.

4. Remove and store the four assembly studs.

5. Install washers and springs on the four shoulder bolts.

6. Apply a small bead of Loctite 518 to the four shoulder bolt threads and install the four shoulder bolts into the piston and piston housing. Tighten the four shoulder bolts to 22-30 lb-ft

(30-40 N•m).

7. Clean and inspect the brake housing, stationary plates and dowels for damage.

NOTE:

The brake housing has TOP identified with a raised lug.

8. Place the brake housing on an assembly bench.

Assemble the eight dowels into the slots in the brake housing.

!

CAUTION



9. Line up all the friction disc splines and grooves in a stack so that they can be assembled this way inside the brake housing.

10. Place a friction disc inside the brake housing.

Place a stationary disc into the brake housing while engaging all the dowels in the disc’s slots.

11. Repeat these steps until completing the assembly stack of discs. Realign all the friction discs’ splines and grooves.

!

WARNING


12. Apply a small, continuous two millimeter bead of

Loctite 518 onto the mounting face of the brake housing and around each bolt hole. Carefully lift the brake housing assembly (lug on TOP) and install it onto the piston housing that is already mounted on the axle.

13. Tighten sixteen M16 x 1.5 threaded capscrews in an “X” torquing pattern to achieve 200-258 lb-ft

(270-350 N•m) bolt torque.

- 35 -

Section 5

Assembly

NOTE:

Use isopropyl alcohol to lubricate the O-ring immediately before this installation of the face seal.

14. Refer to Toric Ring Face Seal into Wheel Hub and Disc Brake Housing, page 37, to install half of the TRS face seal into the brake housing by using tool 860901002T to properly position the

O-ring and steel ring assembly beyond the lip and into the tapered bore in the brake housing.

See Special Tool Section 7, Figure 7.3.

15. Measure the height of the metal face above the housing to ensure the tolerance is within 1 mm variation.

16. Clean and inspect the hub.





NOTE:

Use a Permatex coating to seal against leaks around the hub oil seal. Leaks would result in requiring disassembly, should the leak be noted after the final axle assembly.


21. [Figure 5.6] Use the oil seal driver 0979542000 to install the wheel hub oil seal. See figure for proper seal orientation. Press the seal into the hub until the seal face is flush with the shoulder in the hub bore.

Figure 5.6

22. Refer to Toric Ring Face Seal into Wheel Hub and Disc Brake Housing, page 37, to install the second half of the toric face seal into the hub and cup assembly by using tool 860901002T to properly position the O-ring and steel ring assembly beyond the lip and into the tapered bore in the hub. See Special Tool Section 7,

Figure 7.3

.

23. Measure the height of the metal face above the housing to ensure the tolerance is within 1 mm variation.

!

CAUTION

Do not apply lubricant to the O-ring. Damage and leaks will result.

24. Apply a light coating of lubricant to the two mating surfaces of the face seal’s steel rings only. Do not allow the lubricant to contact the O-ring. Use the same lubricant that was used on the coolant side.

25. Apply a light film of axle lubrication to the hub oil seal rubber lips and wear sleeve contact surface and lead in chamfer.

26. Install the hub with the brake driver splines through the friction discs.

27. Install the outer bearing cone on the spindle.

Install the spindle nut on the spindle. Rotate the hub while tightening the nut as recommended in

Adjust the Wheel Bearing Preload section.

NOTE:

Use isopropyl alcohol to lubricate the

O-ring immediately before this installation.

- 36 -

Section 5

Assembly

Toric Ring Face Seal into Wheel

Hub and Disc Brake Housing

!

CAUTION

Install face seal halves in the same positions where they were located prior to disassembly.

Mixing up face seal halves can cause component damage.

[Figure 5.7]

The TRS Toric Ring Face seal half must be installed in the hub before the hub can be assembled to the spindle. Install the Toric Ring Face seal half in the hub as follows:

Figure 5.7

1

2

3

6

5

4

1. Seal Ring

2. Toric Ring

3. Housing Retainer Lip

4. Housing Ramp

7

5. Seal Ring Housing

6. Seal Ring Face

7. Installation Tool (TC-79461)

!

WARNING

Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-base cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s instructions and these procedures:

•


•


•


•

Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

•

You must use hot solution tanks or alkaline solutions correctly. Carefully follow the manufacturer’s instructions.

!

CAUTION

Check for solvent residue on all seating surfaces.

Solvents that leave a residue on the Toric Ring, metal face seal or on housing seal seating surface can cause the Toric Ring to roll into the seal, rather than slide. Damage to the seal can result.

1. Make sure the formed seal ring, Toric Ring and wheel hub are clean and free of any oil or other contaminants. If required, use a solvent like isopropyl alcohol, that evaporates quickly, leaves no residue, and is compatible with the Toric Ring.

!

CAUTION

Install the Toric Ring into the seal ring and make sure it is flat. Do not twist the Toric Ring when installing onto the seal ring. A twisted Toric Ring will not seal correctly, allowing leakage of lubricant and pumping of debris past the ring.

Damage to components can result.

2. Install the Toric Ring onto the formed seal ring so that it rests in the radius of the tail of the seal ring and is not twisted. Install the Toric Ring onto the seal ring as follows:

- 37 -

Section 5

Assembly

!

CAUTION

Do not use Stanosol ® or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the Toric Ring in the housing, resulting in seal leakage.

A. [Figure 5.8] Wet the rubber Toric Ring with isopropyl alcohol and install it onto the formed seal ring so that it is seated at the bottom of the seal ring ramp and against the retaining lip.

Figure 5.8

4

3

1

2

!

CAUTION

Do not use Stanosol ® or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the

O-ring in the housing, resulting in seal leakage.

3. [Figure 5.10] Coat the Toric Ring with isopropyl alcohol so that it slides easily past the retainer lip in the wheel hub and installs correctly on the spindle ramp.

4. Place installation tool part number TC-79461 (see

Special Tool Section) around the metal seal ring and Toric Ring. Installation tools are available from AxleTech International at in North America

1-877-547-3907, in Europe 33-477-92-8868 or at www.axletech.com/aftermarket.htm.

5. Wipe the O-ring with a lint-free towel or clean foam brush saturated with isopropyl alcohol.

6. [Figure 5.10] Shake excess lubricant from the assembly. Immediately install (“pop”) the seal into the wheel hub with a firm push of the installation tool.

Figure 5.10

1. Seal Ring Ramp 3. Seal Ring Retaining Lip

2. Rubber Toric Ring 4. Seal Ring

B. [Figure 5.9] Make sure the Toric Ring is not twisted by rapidly pulling it away from the seal ring and letting it snap back. Do this in a number of places until the seal is correctly seated. Be careful not to nick or cut the Toric

Ring seal, as this will cause leaks.

Figure 5.9

7. Remove the installation tool.

- 38 -

Section 5

Assembly

8. [Figure 5.11] Follow the same procedure to install the other half of the face seal assembly onto the wet disc brake housing.

Figure 5.11

Check for Correct Installation of the

TRS Toric Ring Seal

Check the spindle and wheel hub for correct installation of the TRS Toric Ring face seal before the hub can be installed onto the spindle.

1. [Figure 5.12] Check assembled height variation

(A) in at least four places, 90 degrees apart, using a caliper, toolmaker’s rule, or other accurately calibrated measuring device. The difference in height around the ring must not be more than 0.5

mm (0.02 inch).

Figure 5.12

2. If required, adjust the seal standout height by using the following methods.

•

If the standout height cannot be brought into specification:

Remove the seal and repeat the installation procedure.

!

CAUTION

Push or pull the Toric Ring and face seal only. Do not push or pull directly on the seal ring. This can cause component damage.

A. Use the installation tool to push down on the

Toric Ring and face seal.

B. With your fingers, pull up uniformly on the


!

CAUTION

Apply isopropyl alcohol to the Toric Ring. Check the retaining lip of the seal seating area for burrs or fins, which can cause a seal to leak. Damage to components can result.

3. Apply isopropyl alcohol as a lubricant to the Toric

Ring and place in the seating area. If installation does not appear smooth, flat and correct, remove the seal from the spindle and repeat the process.

!

CAUTION

To prevent slippage of the Toric Ring, allow sufficient evaporation time for the assembly lubricant before proceeding with further assembly. Damage to components can result.

4. [Figure 5.13] Seat Toric Ring correctly. Once correctly in place, the Toric Ring must roll on ramp only.

Figure 5.13

- 39 -

Section 5

Assembly

Wheel Hub to Spindle Assembly

NOTE:

Complete the assembly of the wheel hub to the spindle. Before installing the wheel hub onto the spindle, however, keep the following points in mind to ensure correct sealing between the faces of the Toric

Ring:

1. Check both sealing faces carefully to make sure they are clean and free of any dirt, debris, lint, and even human hair.

!

CAUTION

Bring the housings together slowly. High impact can result in component damage. Remove protective pad from the spindle's seal journal.

2. Remove the protective pad from the spindle's seal journal.

!

CAUTION

Do not apply lubricant to the Toric Ring. The Toric

Ring can leak. Damage to components can result.

3. Apply a light coating of Dow Corning GN molybdenum assembly paste lubricant to the two mating surfaces of the face seal’s steel rings only.

Do not allow this lubricant to contact the Toric

Ring. The Toric Ring can leak. Figure 4.25.

•

When installing the hub onto the spindle, both seal housings must be aligned correctly.

•

[Figure 5.14]

Slowly bring the hub and spindle assembly together as the spindle bearing adjustment nut is tightened.

Figure 5.14

•

If the seals are not aligned correctly:

The seals will move. Any wobbling motion of the seals is an indication of incorrectly positioned

(cocked) seals. Dirt can enter past the Toric

Ring.

•

[Figure 5.15]

The Toric Rings have slipped, instead of rolling on the left-hand side of the seal. Note how the top Toric Ring is to the right and the bottom Toric Ring is to the left. The same seals are also shown after the bottom half is rotated 90 degrees.

Figure 5.15

•

If the Toric Ring slips at any location,

it will twist, causing the formed seal rings to seat incorrectly (cock).

FACE SEAL

MATING

SURFACES

- 40 -

Section 5

Assembly


NOTE:


!

WARNING









5. Tighten the nut to 200 lb-ft (271 N•m).







•


•


•





!

WARNING






B. apply gear lubricant.

C. Assembly on the planet shaft shoulder 33 needle rollers.


OD and planet gear ID with the grooved face of planet gear down against shaft flange.




5. Install the thrust washer.

6. Install the corresponding O-rings into each planet gears subassembly



- 41 -

Section 5

Assembly


Figure 5.16

Final Assembly

NOTE:










(47 N•m).

Fill Wet Disc Brakes with

Hydraulic Fluid

1. Fill the wet disc brakes with tractor oil universal

(TOU) fluid by using the 0.875"-14 UNF

O-ring plug near the top of the brake and a 0.875"-

14 UNF O-ring plug above the three or nine o’clock position. Fill the brakes until oil exits the lower plug

(above the three or nine o’clock position). Install the lower plug and add two more liters of oil through the top plug.

2. Connect the brake coolant lines and brake actuation lines at the proper locations.

NOTE:

Brake coolant inlet is connected to the 0.875"-

14 UNF O-ring plug at the top position of the brake between the mounting bolts. The brake actuation line is connected at the 0.5625"-18 UNF plug at either the three or nine o’clock position.

3. Thoroughly bleed all the air from the brake actuation system.

4. Preform pressure test on brake apply circuit.

- 42 -

Section 5

Assembly


Wheel End


NOTE:


Assembly.”

Spindle, Brake Spider and Brake

!

WARNING


1. [Figure 5.17] Install two temporary studs (M20 -

2.5 threads, approximately four inches long) into the axle housing flange. Install the studs at the eleven o’clock and one o’clock positions.

Figure 5.17

!

WARNING


3. Apply a 0.125 inch (3.18 mm) diameter continuous bead of silicone gasket material around the flange mounting face of either the axle housing or the spindle. Also apply the gasket material around the edge of all the fastener holes on that surface.

4. [Figure 5.18] Align the flange flats. Install the spindle onto the axle housing.

Figure 5.18

GASKET

MATERIAL



5. Install the brake spider onto the spindle.

6. Install and hand tighten some of the spindle mounting capscrews and washers.

7. Remove the two temporary studs.

8. Install the remaining spindle mounting capscrews and washers. Tighten all capscrews and washers to 370-480 lb-ft (500-650 N•m).

- 43 -

Section 5

Assembly

NOTE:

Replace the camshaft bushing and grease seals before the camshaft bracket is installed onto the brake spider. Refer to Maintenance Manual 4,

Cam Brakes. To order this publication, call

AxleTech’s Customer Service Center at 877-547-3907.

8. Install the brake camshaft bracket with the

O-ring on the pilot onto the brake spider.

9. Install the four mounting capscrews and washers. See "Torque Table" in section 6.

NOTE:

Refer to Maintenance Manual 4, Cam

Brakes; and Automatic Slack Adjuster, to install the brake camshaft, anchor pin components, brake shoes, brake springs, slack adjusters and related parts. To order this publication, call AxleTech’s

Customer Service Center at 877-547-3907.

10. Install the brake camshaft bracket clamp around the bracket tube. Install the two capscrews and washers that mount the clamp to the axle housing. See "Torque Table" in section 6.

11. Install the air chamber-to-bracket mounting nuts. See "Torque Table" in section 6.

12. Attach the chamber push rod yoke to the slack adjuster. See "Torque Table" in section 6.

13. Install the brake dust shield. Tighten the mounting capscrews and washers to

35-50 lb-ft (47-68 N•m).

Wheel End





!

CAUTION

•


NOTE:

Use a Permatex coating to seal against leaks around the hub oil seal. Leaks would result in requiring disassembly, should leak be noted after the final axle assembly.


5. [Figure 5.19] Use the oil seal driver 0979542000 to install the wheel hub oil seal. See figure for proper seal orientation. Press the seal into the hub until the seal face is flush with the hub face.

Figure 5.19

6. Apply a light film of axle lubricant to the hub oil seal rubber lips and wear sleeve contact surface and lead in chamfer.

7. Install the wheel hub, inner bearing and oil seal assembly onto the spindle. Keep the hub assembly aligned with the spindle.

- 44 -

Section 5

Assembly

8. Apply axle lubricant to the outer bearing cone rollers. Install the outer bearing cone onto the ring gear hub.

9. Install the planetary ring gear onto the ring gear hub with lock ring.

10. Install ring gear hub/ring gear onto spindle.

11. Install the wheel bearing adjusting nut.


NOTE:


!

WARNING
















•


•


•





!

WARNING




- 45 -

Section 5

Assembly






OD and planet gear ID with the grooved face of the planet gear down against the shaft flange.




5. Install the thrust washer

6. Install the corresponding O-rings into each planet gears subassembly




Figure 5.20

Final Assembly

NOTE:





3. Install the brake drum over the wheel studs until the drum seats onto the planetary spider flange.


NOTE:

The PRC 785P axle has a common oil level between the carrier and the wheel ends. Three locations must be filled. The vehicle must be on a level surface when filling. Fill to the bottom of each fill plughole. Wait and allow the oil to flow through the axle. Check the oil level again after several minutes and fill to the specified level if necessary.





(47 N•m).

- 46 -

Section 5

Assembly


Wheel End


NOTE:


Assembly.”

Spindle and Piston Housing to the Axle Housing

1. [Figure 5.21] Install two temporary studs

(M20 x 2.5 threads, approximately four inches long) into the axle housing flange. Install the studs at the eleven o’clock and one o’clock positions.

Figure 5.21



!

WARNING


NOTE:

The piston housing has TOP identified by a raised lug.

3. Clean and inspect the spindle and piston housing for damage. Apply a small, two millimeter bead of

Loctite 518 near the OD of the spindle flange and around each bolt hole, on both sides of the spindle flange.

4. Mount the spindle and piston housing (lug on TOP) onto the axle housing using thirteen M20 x 2.5

thread capscrews. Tighten the capscrews in an “X” torquing pattern to achieve 370-480 lb-ft (500-650

N•m) bolt torque.

5. Install 10 mm x 60 mm long assembly studs into the four M8 x 1.25 thread holes in the piston cover.

Wet Disc Brakes

To assemble the PRC 785 W3H wet disc brakes, refer to Maintenance Manual MM-20195, 360 mm

Wet Disc Brakes. To order this publication, call

AxleTech’s Customer Service Center at

877-547-3907.

NOTE:

To continue assembling the PRC 785 W3H wet disc brake wheel end, continue with the following steps.

Wheel End

1. Clean and inspect the piston for damage, inspect the piston grooves to ensure no contaminants remain in the grooves.

2. Apply oil lubricant to the “D” seals and assemble the “D” seals into the appropriate grooves in the piston.

!

WARNING


NOTE:

The piston slightly sticks out of the piston housing.

3. Apply an oil film coating on the piston housing bores. Use “C” clamps to assemble the piston over the assembly studs and push the piston into the piston housing until it bottoms out.

- 47 -

Section 5

Assembly

4. Remove and store the four assembly studs.

5. Install washers and springs on the four shoulder bolts.

6. Apply a small bead of Loctite 518 to the four shoulder bolt threads and install the four shoulder bolts into the piston and piston housing. Tighten the four shoulder bolts to

22-30 lb-ft (30-40 N•m).

7. Clean and inspect the brake housing, stationary plates and dowels for damage.

NOTE:

The brake housing has TOP identified with a raised lug.

8. Place the brake housing on an assembly bench.

Assemble the eight dowels into the slots in the brake housing.

!

CAUTION



9. Line up all the friction disc splines and grooves in a stack so that they can be assembled this way inside the brake housing.

10. Place a friction disc inside the brake housing.

Place a stationary disc into the brake housing while engaging all the dowels in the disc’s slots.

11. Repeat these steps until completing the assembly stack of discs. Realign all the friction disc splines and grooves.

NOTE:

Use isopropyl alcohol to lubricate O-ring immediately before this installation of the face seal.

14. Refer to Toric Ring Face Seal into Wheel Hub and Disc Brake Housing, page 49, to install half of the TRS face seal into the brake housing by using tool 860901002T to properly position the

O-ring and steel ring assembly beyond the lip and into the tapered bore in the brake housing.

See Special Tool Section 7, Figure 7.3.

15. Measure height of metal face above housing and insure tolerance is within 1 mm variation.

16. Clean and inspect the hub.





NOTE:

Use a Permatex coating to seal against leaks around the hub oil seal. Leaks would result in requiring disassembly, should the leak be noted after the final axle assembly.


21 [Figure 5.22] Use the oil seal driver 0979542000 to install the wheel hub oil seal. See figure for proper seal orientation. Press the seal into the hub until the seal face is flush with the shoulder in the hub bore.

Figure 5.22

!

WARNING


12. Apply a small, continuous two millimeter bead of

Loctite 518 onto the mounting face of the brake housing and a round each bolt hole. Carefully lift the brake housing assembly (lug on TOP) and install it onto the piston housing that is already mounted on the axle.

13. Tighten sixteen M16 x 1.5 threaded capscrews in an “X” torquing pattern to achieve 200-258 lb-ft

(270-350 N•m) bolt torque.

- 48 -

NOTE:

Use isopropyl alcohol to lubricate O-ring immediately before this installation.

Section 5

Assembly

22. Refer to Toric Ring Face Seal into Wheel Hub and Disc Brake Housing, page 49, to install the second half of the toric face seal into the hub and cup assembly by using tool 860901002T to properly position the O-ring and steel ring assembly beyond the lip and into the tapered bore in the hub. See Special Tool Section 7,

Figure 7.3

.

23. Measure height of metal face above housing to ensure tolerance is within 1 mm variation.

!

CAUTION

Do not apply lubricant to the O-ring. Damage and leaks will result.

24. Apply a light coating of lubricant to the two mating surfaces of the face seal’s steel rings only. Do not allow lubricant to contact the O-ring. Use the same lubricant that was used on the coolant side.

25. Apply a light film of axle lubrication to the hub oil seal rubber lips and wear sleeve contact surface and lead in chamfer.

26. Install the hub with brake driver splines through the friction discs.

27. Install the outer bearing cone on the spindle.

Install the spindle nut on the spindle. Rotate the hub while tightening the nut as recommended in

Adjust the Wheel Bearing Preload section.

Toric Ring Face Seal into Wheel

Hub and Disc Brake Housing

!

CAUTION

Install face seal halves in the same positions where they were located prior to disassembly.

Mixing up face seal halves can cause component damage.

[Figure 5.23]

The TRS Toric Ring Face seal half must be installed in the hub before the hub can be assembled to the spindle. Install the Toric Ring Face seal half in the hub as follows:

Figure 5.23

1

6

2

3

4

5

7

1. Seal Ring

2. Toric Ring

3. Housing Retainer Lip

4. Housing Ramp

5. Seal Ring Housing

6. Seal Ring Face

7. Installation Tool (TC-79461)

!

WARNING

Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and petroleum-base cleaners. To avoid serious personal injury when you use solvent cleaners, you must carefully follow the manufacturer’s instructions and these procedures:

•


•


•


•

Do not use gasoline, or solvents that contain gasoline. Gasoline can explode.

•

You must use hot solution tanks or alkaline solutions correctly. Carefully follow the manufacturer’s instructions.

!

CAUTION

Check for solvent residue on all seating surfaces.

Solvents that leave a residue on the Toric Ring, metal face seal or on housing seal seating surface can cause the Toric Ring to roll into the seal, rather than slide. Damage to the seal can result.

1. Make sure the formed seal ring, Toric Ring and wheel hub are clean and free of any oil or other contaminants. If required, use a solvent like isopropyl alcohol, that evaporates quickly, leaves no residue, and is compatible with the Toric Ring.

- 49 -

Section 5

Assembly

!

CAUTION

Install the Toric Ring into the seal ring and make sure it is flat. Do not twist the Toric Ring when installing onto the seal ring. A twisted Toric Ring will not seal correctly, allowing leakage of lubricant and pumping of debris past the ring.

Damage to components can result.

2. Install the Toric Ring onto the formed seal ring so that it rests in the radius of the tail of the seal ring and is not twisted. Install the Toric Ring onto the seal ring as follows:

!

CAUTION

Do not use Stanosol ® or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the Toric Ring in the housing, resulting in seal leakage.

A. [Figure 5.24] Wet the rubber Toric Ring with isopropyl alcohol and install it onto the formed seal ring so that it is seated at the bottom of the seal ring ramp and against the retaining lip.

Figure 5.24

4

3

1

2

Figure 5.25

!

CAUTION

Do not use Stanosol ® or any other liquid that leaves an oily film and does not evaporate quickly, since this may result in incorrect seating of the

O-ring in the housing, resulting in seal leakage.

3. [Figure 5.26] Coat the Toric Ring with isopropyl alcohol so that it slides easily past the retainer lip in the wheel hub and installs correctly on the spindle ramp.

4. Place installation tool part number TC-79461 (see

Special Tool Section) around the metal seal ring and Toric Ring. Installation tools are available from AxleTech International at in North America

1-877-547-3907, in Europe 33-477-92-8868 or at www.axletech.com/aftermarket.htm.

5. Wipe the O-ring with a lint-free towel or clean foam brush saturated with isopropyl alcohol.

6. [Figure 5.26] Shake excess lubricant from the assembly. Immediately install (“pop”) the seal into the wheel hub with a firm push of the installation tool.

Figure 5.26

1. Seal Ring Ramp

2. Rubber Toric Ring

3. Seal Ring Retaining Lip

4. Seal Ring

B. [Figure 5.25] Make sure the Toric Ring is not twisted by rapidly pulling it away from the seal ring and letting it snap back. Do this in a number of places until the seal is correctly seated. Be careful not to nick or cut the Toric

Ring seal, as this will cause leaks.

- 50 -

Section 5

Assembly

7. Remove the installation tool.

8. [Figure 5.27] Follow the same procedure to install the other half of the face seal assembly onto the wet disc brake housing.

Figure 5.27

Check for Correct Installation of the

TRS Toric Ring Seal

Check the spindle and wheel hub for correct installation of the TRS Toric Ring face seal before the hub can be installed onto the spindle.

1. [Figure 5.28] Check assembled height variation

(A) in at least four places, 90 degrees apart, using a caliper, toolmaker’s rule, or other accurately calibrated measuring device. The difference in height around the ring must not be more than 0.5

mm (0.02 inch).

Figure 5.28

2. If required, adjust the seal standout height by using the following methods.

•

If the standout height cannot be brought into specification:

Remove the seal and repeat the installation procedure.

!

CAUTION

Push or pull the Toric Ring and face seal only. Do not push or pull directly on the seal ring. This can cause component damage.

A. Use the installation tool to push down on the


B. With your fingers, pull up uniformly on the Toric

Ring and face seal.

!

CAUTION

Apply isopropyl alcohol to the Toric Ring. Check the retaining lip of the seal seating area for burrs or fins, which can cause a seal to leak. Damage to components can result.

3. Apply isopropyl alcohol as a lubricant to the Toric

Ring and place in the seating area. If installation does not appear smooth, flat and correct, remove the seal from the spindle and repeat the process.

!

CAUTION

To prevent slippage of the Toric Ring, allow sufficient evaporation time for the assembly lubricant before proceeding with further assembly. Damage to components can result.

4. [Figure 5.29] Seat Toric Ring correctly. Once correctly in place, the Toric Ring must roll on ramp only.

Figure 5.29

- 51 -

Section 5

Assembly

Wheel Hub to Spindle Assembly

NOTE:

Complete the assembly of the wheel hub to the spindle. Before installing the wheel hub onto the spindle, however, keep the following points in mind to ensure correct sealing between the faces of the

Toric Ring:

1. Check both sealing faces carefully to make sure they are clean and free of any dirt, debris, lint, and even human hair.

!

CAUTION

Bring the housings together slowly. High impact can result in component damage. Remove protective pad from the spindle's seal journal.

2. Remove the protective pad from the spindle's seal journal.

!

CAUTION

Do not apply lubricant to the Toric Ring. The

Toric Ring can leak. Damage to components can result.

3. Apply a light coating of Dow Corning GN molybdenum assembly paste lubricant to the two mating surfaces of the face seal’s steel rings only.

Do not allow this lubricant to contact the Toric

Ring. The Toric Ring can leak. Figure 4.30.

•

When installing the hub onto the spindle, both seal housings must be aligned correctly.

•

[Figure 5.30]

Slowly bring the hub and spindle assembly together as the spindle bearing adjustment nut is tightened.

Figure 5.30

FACE SEAL

MATING

SURFACES

•

If the seals are not aligned correctly:

The seals will move. Any wobbling motion of the seals is an indication of incorrectly positioned

(cocked) seals. Dirt can enter past the Toric

Ring.

•

[Figure 5.31]

The Toric Rings have slipped, instead of rolling on the left-hand side of the seal. Note how the top Toric Ring is to the right and the bottom Toric Ring is to the left. The same seals are also shown after the bottom half is rotated 90 degrees.

Figure 5.31

•

If the Toric Ring slips at any location,

it will twist, causing the formed seal rings to seat incorrectly (cock).


NOTE:


- 52 -

!

WARNING






0979534000. Tighten further until one of the nut’s scallops lines-up with one of the threaded holes in the ring hub. See special tool section.

See "Torque Table" in section 6.

Section 5

Assembly









•


•


•





!

WARNING









OD and planet gear ID with the grooved face of the planet gear down against the shaft flange.




5. Install the thrust washer.

6. Install the corresponding O-rings into each planet gears subassembly.




Figure 5.32

- 53 -

Section 5

Assembly

Final Assembly

NOTE:










(47 N•m).

Fill Wet Disc Brakes with

Hydraulic Fluid

1. Fill the wet disc brakes with tractor oil universal

(TOU) fluid by using the 0.875"-14 UNF

O-ring plug near the top of the brake and a

0.875"-14 UNF O-ring plug above the three or nine o’clock position. Fill the brakes until oil exits the lower plug (above the 3 or 9 o’clock position).

2. Connect brake coolant lines and brake actuation lines at the proper locations.

NOTE:

Brake coolant inlet is connected to the

0.875"-14 UNF O-ring plug at the top position of the brake between the mounting bolts. The brake actuation line is connected at the 0.5625"-18 UNF plug at either the three or nine o’clock position.

3. Thoroughly bleed all air from brake actuation system.

4. Preform pressure test on brake apply circuit.

- 54 -

Section 6

Specifications

PRC 485 Q Plus™ Wheel End Torque Chart

4

1

7

10

9

5

8

3

11

6

2

Item

7

8

5

6

3

4

1

2

9

10

11

Fastener

Wheel rim nut

Oil fill/level/drain plug

Spindle and brake spider mounting (drum)

Camshaft bracket clamp

Camshaft bracket to spider

Wheel bearing adjusting nut

Adjusting nut set screw

Dust shield mounting 3/8”-16 grade 8

Air chamber mounting

Push rod locknut 5/8”-18

Planetary spider-to-wheel hub slotted head screw

- 55 -

Torque Value

Per OEM specification

35 lb-ft (47 N•m)

200-260 lb-ft (270-350 N•m)

35-50 lb-ft (47-68 N•m)

90-120 lb-ft (122-163 N•m) - not shown

400 lb-ft (542 N•m)

35 lb-ft (47 N•m)

30-50 lb-ft (41-68 N•m) - not shown

133-155 lb-ft (180-210 N•m) - not shown


Refer to instructions in Section 3

Section 6

Specifications

PRC 485 W3H Wheel End Torque Chart

6

1

4

3

7

5

2

Item

7

8

5

6

3

4

1

2

Fastener

Wheel rim nut

Spindle and wet disc brake housing mounting



Brake housing capscrews

Piston return spring shoulder bolts

Oil fill/drain plug (not shown)


8

Torque Value


370-480 lb-ft (500-650 N•m) - not shown

400 lb-ft (542 N•m)

35 lb-ft (47 N•m)

200-258 lb-ft (270-350 N•m)

22-30 lb-ft (30-40 N•m)

35 lb-ft (47 N•m)

Hand tighten (No spcification)

- 56 -

Section 6

Specifications

PRC 785P Wheel End Torque Chart

6

10

9

5

8

4

1

3

3

2

7

Item

7

8

5

6

3

4

1

2

9

10

11

Fastener

Wheel rim nut



Camshaft bracket to spider

Camshaft bracket clamp

Spindle and brake mounting (drum)

Oil fill/drain plug

Dust shield mounting 3/8”-16 grade 8

Air chamber mounting

Push rod locknut 5/8”-18


- 57 -

Torque Value


400 lb-ft (542 N•m)

35 lb-ft (47 N•m)

90-120 lb-ft (122-163 N•m)

35-50 lb-ft (47-68 N•m)

370-480 lb-ft (500-650 N•m)

35 lb-ft (47 N•m) -


133-155 lb-ft (180-210 N•m) - not shown


Hand tighten (No spcification)

Section 6

Specifications

PRC 785 W3H Wheel End Torque Chart

7

4

1

3

2

6

5

6

Item

5

6

7

3

4

1

2

Fastener

Wheel rim nut



Spindle and wet disc brake mounting

Brake housing capscrews

Oil fill/drain plug

Piston return spring shoulder bolts

Torque Value


400 lb-ft (542 N•m)

35 lb-ft (47 N•m)

370-480 lb-ft (500-650 N•m)

200-258 lb-ft (270-350 N•m)

35 lb-ft (47 N•m)

22-30 lb-ft (30-40 N•m)

- 58 -

Section 6

Specifications

Lubrication Specification

NOTE:

Do not fill only through the axle housing bowl. For axles with a common level, fill the axle at each wheel end and the axle housing bowl to the bottom of the fill/level plug hole with the specified oil.

Wait and allow the oil to flow through the axle. Check the oil level again and fill to the specified level if necessary.

Lubrication Schedule

Operation

Initial Oil Change

Check Oil Level

Petroleum Oil

Change

Synthetic Oil or

Semi-Synthetic Oil

Change

Off-Highway

➀

250 operating hours➀

250 operating hours➀

1,500 operating hours or twice a year

(whichever comes first)➀

3,000 operating hours or once a year

(whichever comes first)

➀

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

Lubrication Specifications

AxleTech

Specifications

O-76A, Gear Oil

O-76D, Gear Oil

O-76E, Gear Oil

O-76L, Gear Oil

O-76M, Gear Oil

O-76N, Gear Oil

SAE

Specification

Approval

SAE J 2360

Oil

Description

GL-5, SAE 85W/140

GL-5, SAE 80W/90

GL-5, SAE 75W/90

GL-5, SAE 75W/140

GL-5, SAE 75W/140

GL-5, SAE 75W/140

Min.

10

-15

-40

-40

-40

-40

Outside Temperature

°F °C

Max.

None

None

None

None

None

None

Min.

-12

-26

-40

-40

-40

-40

Max.

None

None

None

None

None

None

Specification

Tractor oil universal (TOU)

Oil Description

SAE 10W, 20W or 10W30

- 59 -

Section 6

Specifications

Wet Disc Brake Coolant Specifications

Sump and Forced Cooling Systems with Hub Seals

Coolant

Petroleum Base

SAE 10W, SAE 20W or SAE 10W30

Specification

See the recommendations of the vehicle manufacturer.

•

Use tractor oil universal fluid (“TOU” types) formulated for wet disc brakes in the wet disc brake housing. Make sure that the specifications of the tractor fluid are the same as the specifications of the vehicle manufacturer.

!

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 assure the coolant temperature remains below 250°F (120°C).

Coolant Change Intervals

Break-In Interval:

Change the fluid in the brake housing after the first month or the first 200-250 hours of operation, whichever comes first.

Normal Maintenance Interval:

Change the fluid every 6 months or every 3000 hours of operation, whichever comes first.

Hydraulic Fluid Specifications

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.

- 60 -

Section 7

Special Tools & Procedures

Spindle Nut Tool

Figure 7.1

TOOL 0979534000

Planetary Spider Assembly Tool

Figure 7.2

TOOL 0979539000 FOR PRC 785

TOOL 0979600000 FOR PRC 485

Toric Ring Face Seal Assembly Tool

Figure 7.3

TOOL 860901002T

TRS TORIC RING FACE

SEAL INSTALLATION

- 61 -

Suite 400

3001 West Big Beaver Road

Troy, Michigan 48084

U.S.A.

Toll Free: 877-877-9717

Non-Toll Free: 248-816-5401

Fax: 248-435-1990

Website: www.axletech.com

MM9N

Issued 03-07

AxleTech International France

4, Rue Jean Servanton

Boite Postale 656

42042 Saint Etienne Cédex 1

France

(33) 477.92.88.00

Fax: (33) 477.92.88.93

© Copyright AxleTech International

Printed in the USA

AxleTech do Brasil Sistemas Automotivos Ltda.

Avendia Joao Batista, 830

Centro-Osasco-SP

06097095 Brasil

Phone: +55 11 36846641

Fax: +55 11 36846859

AxleTech PRC 785P, PRC 485Q, PRC 785 W3H, PRC 485 W3H planetary axle Maintenance Manual

Assistant Bot

Planetary Axle Wheel Ends

Extrémité de roue à réduction planétaire

Maintenance Manual 9N

Manuel de maintenance 9N

Issued 03-07

Edité Marche 07

Before You Begin

Safety Alerts, Torque Symbol and Notes

Additional Publications

How To Order

Description

Identification

PRC 485Q (with Q Plus™ Cam Brakes) Wheel End Cross Section

PRC 485Q (with Q Plus™ Cam

Brakes) Planetary Axle

Wheel End

Brake Drum

Planetary Spider Assembly

Cam Brakes

Spindle and Brake Spider

PRC 485 W3H Wheel End Cross Section

PRC 485 W3H Wet Disc Brake

Wheel End

Preliminary Disassembly

Planetary Spider Assembly

Wheel End

Spindle and Piston Housing

Wet Disc Brakes

PRC 785P Wheel End Cross Section

PRC 785P Planetary Axle

Wheel End

Brake Drum

Planetary Spider Assembly

Cam Brakes

Spindle and Brake Spider

PRC 785 W3H Wheel End Cross Section

PRC 785 W3H Wet Disc Brake

Wheel End

Preliminary Disassembly

Planetary Spider Assembly

Wheel End

Spindle and Piston Housing

Wet Disc Brakes

Clean Ground or Polished

Parts

Clean Parts with a

Rough Finish

Clean Axle Assemblies

Dry Cleaned Parts

Prevent Corrosion

Inspect Parts

Inspect Tapered Roller Bearings

Inspect the Bevel Pinion and Ring

Gear Sets

Inspect the Main Differential

Assembly

Inspect the Axle Shafts

Inspect the Yoke

Inspect the Brakes

Repair or Replace Parts

Repair Welding

Apply Silicone Gasket Material

(All Specs Spindle To Housing

Joint)

PRC 485Q (with Q Plus™ Cam

Brakes) Planetary Axle

Wheel End

Prepare Parts for Assembly

Spindle, Brake Spider and Brake

Wheel End

Adjust the Wheel Bearing Preload

Planetary Spider and

Gearing Assembly

Final Assembly

PRC 485 W3H Wet Disc Brake

Wheel End

Prepare Parts for Assembly

Spindle and Piston Housing to the Axle Housing