48T300 Service Manual 0183

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Service Manual

Industrial Planetary Axles - Heavy

Planetary Rigid

48T300

ASM-0117

August 2008

48T300 Drive Axle

Service Manual

NOTES

1

48T300 Drive Axle

Service Manual

FOREWORD

This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Products.

Extreme care has been exercised in the design and selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service.

In order to become familiar with the various parts of the product, it’s principle of operation, troubleshooting, and adjustments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations.

Whenever repair or replacement of component parts is required, only Dana approved parts as listed in the applicable parts manual should be used. Use of “will fit” or non-approved parts may endanger proper operation and performance of the equipment.

Dana does not warrant repair, replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana. Important: Always furnish serial and model numbers when ordering parts.

SAFETY PRECAUTIONS

To reduce the chance of personal injury and/or property damaged, the following instructions must be carefully observed.

Proper service and repair are important to the safety of the service technician and the safe, reliable operation of the machine. If replacement parts are required the part must be replaced with a Dana specified replacement part. Do not use a replacement part of lesser quality.

The service procedures recommended in this manual are effective methods of performing service and repair. Some of these procedures require the use of purpose designed tools.

Accordingly, anyone who intends to use a replacement part, service procedure or tool which is not recommended must first determine that neither his safety or the safe operation of the machine will be jeopardized by the replacement part, service procedure or tool selected.

It is important to note that this manual contains various “Cautions and Notices” that must be carefully observed in order to reduce the risk of personal injury during service or repair. Improper service or repair may damage the unit or render it unsafe. It is important to understand that these “Cautions and Notices’ are not exhaustive. It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions.

2

48T300 Drive Axle

Service Manual

TABLE OF CONTENTS

39

39

42

42

34

37

37

38

43

44

46

48

49

30

32

33

34

27

27

28

29

13

14

15

17

9

10

11

12

5

6

7

8

Page

2

3

4

22

23

24

25

26

18

19

20

21

Foreword And Safety Precautions

Table of Contents

Description

Axle Assembly Exploded View

Axle Assembly Parts Description

Diff. and Carrier Assembly Exploded View

Diff. and Carrier Assembly Parts Description

Brake Assembly Exploded View

Brake Assembly Parts Description

Planet Assembly Parts Description

Oil Checking Procedure

Recommended Lubricants

Bearing Heating and Freezing Guidelines

Cleaning and Inspection

Axle Reassembly

Pinion Depth Setting Procedure

Wheel Bearing Adjusting Instructions

Face Seal Installation Instructions

Posi-Stop Brake Pressure Test Instructions

Axle Pressure Test Instructions

Tooth Bearing Chart - LH

Tooth Bearing Chart - RH

Fastener Torque Chart

Plug and Elastic Stop Nut Torque Charts

DISASSEMBLY SECTION

Axle Disassembly

Planetary Removal

Axle Shaft and Hub Removal

Face Seal Removal

Brake and Spindle Removal

Output Flange and Bearing Removal

Differential and Carrier Assembly Removal

Planetary Disassembly

Hub Disassembly

Posi-Stop Brake Disassembly

Brake Cover Removal

Brake Discs, Piston and Spring Removal

Wear Indicator Pin Removal

Piston Removal

Differential and Carrier Disassembly

Input Flange Removal

Differential and Ring Gear Removal

Input and Drop Gear Shaft Removal

Pinion and Drop Gear Removal

Ring Gear Removal

Differential Disassembly

79

81

82

84

86

87

89

90

73

73

74

75

75

76

77

78

90

91

92

60

60

61

63

66

67

71

72

52

52

53

54

55

55

55

56

57

58

93

95

98

99

100

101

102

REASSEMBLY SECTION

Axle Reassembly

Planetary Reassembly

Hub Reassembly

Internal Ring Gear Assembly & Installation

Posi-Stop Brake Reassembly

Wear Indicator Pin Installation

Pressure Ring and Spring Installation

Brake Disc Installation

Piston Installation

Cover Installation

Differential and Carrier Reassembly

Calculating and Installing Pinion Shims

Pinion Gear Installation and Preload

Input and Drop Gear Shaft Installation

Setting Input and Drop Gear Shaft End Play

Differential Body Assembly

Ring Gear Installation

Diff. Body and Ring Gear Installation

Carrier Cap Installation

Setting Ring Gear Backlash

Drop Gear Cover Installation

Input Flange Spacer Installation

Carrier Cover Installation

Input Flange Installation

Checking Ring Gear Contact Pattern

Thrust Screw Installation

Spindle and Brake Installation

Hub Installation

Face Seal Installation

Wheel Bearing Preload Adjustment

Brake Cavity and Seal Air Test

Differential and Carrier Installation

Output Bearing & Seal Retainer Installation

Axle Shaft and Sun Gear Installation

Planetary Installation

Output Flange Installation

Axle Air Pressure Test

SPECIAL TOOL SECTION

Brake Spring Compression Tool Instructions

Brake Spring Compression Tool Drawing

Brake Piston Lifting Tool

Wheel Hub and Brake Lifting Tool

Pinion Locking Tool

Pinion Pressing Tool

Hub Seal Driver

3

48T300 Drive Axle

Service Manual

DESCRIPTION

The axle assembly has a bevel type ring gear and pinion with further reduction provided by a planetary gear set within the wheel hub.

Primary Reduction

The spiral bevel pinion and ring gear transmit power through the center differential pinions, side gears, and to the axle shaft. The spiral bevel differential assembly is mounted on tapered roller bearings which are adjusted by the positioning of the two threaded adjusting nuts mounted in the differential carrier and cap assembly. The pinion bearing preload is adjusted and maintained by a hardened and precision ground spacer positioned between inner and outer bearings. The spacer is selected at assembly.

Secondary Reduction

In the wheel hub, a self-centering sun gear is spline fitted to the axle shaft and drives three planetary pinion gears. These gears in turn mesh with and react against a rigidly mounted internal ring gear. The planet gears rotate on needle roller bearings mounted on hardened and ground pins located in the planet carrier which in turn drive the wheel hub. Positive lubrication keeps all moving parts bathed in lubricant to reduce friction, heat and wear.

Posi-Stop (LCB) Liquid Cooled Brakes

The liquid cooled brake is ideal for use in contaminated or temperature sensitive environments and in machines where extra long maintenance intervals are required.

Braking action of the Posi-Stop LCB is achieved through the application of the hydraulic piston and brake apply springs with the rotating friction surfaces which react with stationary stator plates. The stator plates are retained by scalloped tangs at the outside diameter, which in turn transfer the reaction torque to the rigid outside housing.

Hub splines are long enough to engage all friction discs before bearings or seals are set.

This provides ease of service reassembly.

Wheel bearings are serviced as in any normal bearing service procedure.

4

48T300 Drive Axle

Service Manual

AXLE ASSEMBLY PARTS DESCRIPTION

Item Description

1 Cotter Pin - Input & Drop Gear Shaft Nut

2 Nut - Input & Drop Gear Shaft Flange

3 Washer - Input & Drop Gear Shaft

4 Flange - Input & Drop Gear Shaft Output

5 Shield - Output Flange Dust

6 Oil Seal - Input & Drop Gear Shaft

7 Nut - Bearing and Seal Retainer

8 Lockwasher - Bearing and Seal Retainer

9 Stud - Bearing and Seal Retainer

10 Retainer - Bearing and Oil Seal

11 O-Ring - Bearing and Seal Retainer

12 Bearing - Roller

13 Spacer - Bearing

14 Bearing - Roller

15 Plug - Axle Housing Filler

16 Non Serviceable Item

17 Screw - Plate

18 Cap screw - Planetary Mounting

19 Plug - Planetary Level & Drain

21 Planetary Assembly

22 O-ring - Planetary Assembly Sealing

23 Cap screw - Adjusting Nut Lock

24 Lock Plate - Wheel Bearing Adjusting Nut

25 Nut - Wheel Bearing Adjusting

26 Gear - Internal

27 Internal Hub

28 Snap Ring

1

N/A

2

6

1

1

1

1

7

1

7

7

1

1

Qty

1

1

1

1

2

2

2

2

2

2

2

2

12

Item Description

29 Gear - Sun

30 Cone - Outer Wheel Hub Bearing

31 Cup - Outer Wheel Hub Bearing

32 Hub - Wheel

33 Seal - Face

34 Cup - Inner Hub Bearing

35 Cone - Inner Hub Bearing

36 Oil Seal - Hub

37 Cap screw - Brake & Spindle Mounting

38 Washer - Brake & Spindle Mounting

39 Retaining Ring - Spindle

40 Brake Assembly

41 Sealing Ring - Brake To Spindle

42 Spindle

43 Sealing Ring - Spindle To Axle Housing

44 Sealing Ring - Spindle Pilot

45 Shaft - Axle

46 Housing - Axle

47 Plug - Magnetic Drain

48 Stud - Differential Mounting 3.687" Long

49 Nut - Differential Mounting

50 Washer - Differential Mounting

51 Stud - Differential Mounting 4.720" Long

52 Dowel Tapered - Differential Mounting

53 Stud - Differential Mounting 2.750" Long

54 Nut - Differential Mounting

55 Differential Assembly

2

1

2

2

26

26

2

2

2

2

2

2

2

2

Qty

2

2

2

2

2

4

10

11

1

1

2

3

14

6

48T300 Drive Axle

Service Manual

DIFFERENTIAL AND CARRIER EXPLODED VIEW

7

48T300 Drive Axle

Service Manual

DIFFERENTIAL AND CARRIER PARTS DESCRIPTION

Item Description

1 Cotter Pin - Input Flange Nut

2 Nut - Input Flange

3 Washer - Input Flange

4 Flange - Input

5 Shield - Input Flange Dust

6 Oil Seal - Input Shaft

7 Capscrew - Carrier Cover

8 Lockwasher - Carrier Cover Capscrew

9 Cover - Carrier

10 Spacer - Input Flange To Bearing

11 Capscrew - Input Shaft Bearing Retainer

12 Lockwasher - Input Shaft Brg. Retainer

13 Retainer - Input Shaft Outer Bearing

14 Shim - Input Shaft Bearing Retainer .004"

15 Shim - Input Shaft Bearing Retainer .007"

16 Shim - Input Shaft Bearing Retainer .010"

17 Cup - Input Shaft Bearing

18 Cone - Input Shaft Bearing

19 Screw - Thrust

20 Nut - Thrust Screw

21 Nut - Differential Adjusting

22 Cup - Differential Bearing

23 Cone - Differential Bearing

24 Gear - Input Drop

25 Cover - Drop Gear Access

26 Lockwasher - Drop Gear Access Cover

27 Capscrew - Drop Gear Access Cover

28 Stud - Carrier Cap

29 Washer - Carrier Cap

30 Nut - Carrier Cap Stud

31 Shaft - Input and Drop Gear

32 Bearing Cone - Input Shaft

33 Bearing Cup - Input Shaft

34 Washer - Snap Ring

35 Snap Ring - Bearing Retaining

4

1

4

4

6

6

1

1

1

1

1

1

2

2

1

2

AR

1

1

1

8

1

AR

AR

11

1

1

8

1

1

1

11

Qty

1

1

1

Item Description

36 Capscrew - Ring Gear

37 Nut - Ring Gear Capscrew

38 Flanged Half - Differential Case

39 Gear - Ring

40 Clutch Disc - Differential Outer

41 Clutch Disc - Differential Inner

42 Side Gear - Differential

43 Spider - Differential

44 Spacer - Inner Bearing Roller

45 Roller - Bearing

46 Spacer - Center & Outer Bearing Roller

47 Gear - Differential Pinion

48 Washer - Pinion Thrust

49 Plain Half - Differential Case

50 Washer - Differential Case Capscrew

51 Capscrew - Differential Case

52 Capscrew - Differential Case

53 Gear - Pinion

54 Bearing Cone - Pinion Inner

55 Bearing Cup - Pinion Inner

56 Shim - Pinion Bearing Cup .004"

57 Shim - Pinion Bearing Cup .007"

58 Shim - Pinion Bearing Cup .010"

59 Kit - Inner Pinion Bearing Spacer & Shim

60 Capscrew - Diff. Adjusting Nut Lock

61 Lockwasher - Diff. Adjusting Nut Lock

62

Cap - Carrier

63 Assembly - Differential Carrier & Cap

64 Plug - Drain

65 Gear - Pinion Drop

66 Spacer - Outer Pinion Bearing

67 Cup - Outer Pinion Bearing

68 Cone - Outer Pinion Bearing

69 Washer - Pinion Nut

70 Nut - Pinion

71 Cotter Pin - Pinion Nut

1

AR

AR

AR

1

1

8

4

1

2

2

4

4

1

12

1

4

232

8

6

2

1

8

Qty

12

12

1

1

1

1

1

1

1

1

1

2

1

8

48T300 Drive Axle

Service Manual

BRAKE EXPLODED VIEW

9

48T300 Drive Axle

Service Manual

BRAKE PARTS DESCRIPTION

Item Description

1 Snap Ring - Indicator

2 O-Ring - Indicator Pin

3 Pin - Wear Indicator

4 & 5 Non Serviceable Item

6 Plug - Actuating Port

7 Plug - Cooling Outlet Port

8 O-Ring - Cooling Outlet Port Plug

9 Plug - Cooling Outlet Port

10 O-Ring - Cooling Outlet Port Plug

11 O-Ring - Actuating Port Plug

12 Screw - Bleeder

13 Housing - Brake

14 Spring - Brake Apply Outer

15 Spring - Brake Apply Inner

16 Sealing Ring - Pressure Ring

17 Pressure Ring - Piston

1

1

1

1

1

1

1

Qty

1

2

1

N/A

1

15

15

1

1

Item Description

18 Disc - Reaction

19 Disc - Friction

20 Sealing Ring - Brake Cover

21 Seal Assembly - Piston Outer

22 Piston - Brake

23 Seal Assembly - Piston Inner

24 Cover - Brake Outer

25 Sealing Ring - Port Square Cut

26 Sticker - Warning

27 Cover - Sticker

28 Capscrew - Sticker Cover

29 O-Ring - Port Plug

30 Plug - Port

31 Washer - Outer Cover Capscrew

32 Capscrew - Outer Cover Attaching

2

4

2

2

2

2

1

1

1

24

24

Qty

5

5

1

1

10

48T300 Drive Axle

Service Manual

PLANET EXPLODED VIEW AND PARTS DESCRIPTION

Item Description

1 Snap Ring - Planetary Gear Bearing

2 Bearing - Planetary Gear

3 Gear - Planetary

Qty

4

4

4

Item Description

4 Carrier - Planetary

5 Washer - Sun Gear Thrust

Qty

1

1

11

48T300 Drive Axle

Service Manual

OIL CHECKING PROCEDURE

Check lubricant level after each 250 hours of operation. Always maintain lubricant level to bottom of filler plug hole. Drain oil every 2,500 hours or within one year. To check oil level in axles with differential drive and planetary wheel ends, the axle should be run first, then allowed to stand for a minimum of five minutes on level ground. This procedure will allow oil to drain back to its normal level. After the five-minute interval, remove oil plug at axle center and in the planetary wheel ends for oil level inspection. If oil level is not at the bottom of the filler hole, add necessary lubricant.

CHECKING OIL LEVEL IN PLANETARY WHEEL ENDS

Always check lubricant in planetary wheel ends with arrow on the planetary carrier face in the

6:00 o’clock position. Remove oil level plug, if lubricant is below oil level hole add necessary lubricant.

DRAINING AXLE CENTER AND WHEEL ENDS

Draining is best accomplished immediately after the vehicle has been operating. The lubricant is then warm and will flow freely allowing full drainage in minimum time. This is particularly desirable in cold weather.

Remove plug at bottom of axle housing and the filler plug on the planetary wheel ends, making sure the planetary filler hole is down when draining. Allow sufficient time for the lubricant to drain, then replace plugs and refill with recommended lubricant.

When refilling be sure the arrow on the planetary carrier face is in the 6:00 o’clock position, allow the lubricant time to drain back to its normal level.

FLUSHING

After draining, axles should be flushed. Replace drain plugs and fill axles to the proper level with a

#2 diesel fuel. Operate the vehicle for a short period of time in low gear and not more than 1500 engine rpm. Wide turns both left and right should be made to work the differential, then drain. Be sure to drain all of the flushing oil before refilling with new oil by following the draining procedure above, make sure all the flushing oil has been removed. Inspect the magnetic drain plug for metal particles or other foreign matter indicative of wear or possible failure. Then fill with the recommended lubricant.

Note: When filling the axle housing, planetary wheel ends, and brakes, allow enough time for lubricant to flow through the various components in the differential, planetary housing, and the brake assembly. After filling is completed, allow a few minutes for lubricant to attain its level and recheck each wheel end and the axle center. Add lubricant if necessary.

12

48T300 Drive Axle

Service Manual

RECOMMENDED LUBRICANTS

Recommendations: Extreme pressure gear lubricant is recommended for use in all drive-steer and rigid drive axles except where explicitly stated differently by Spicer Off-Highway Products

Engineering.

Mineral Based: Acceptable lubricants must meet API GL-5/MT or MIL-PRF2105E qualifications.

The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below.

Synthetics: Synthetic lubricants are recommended providing they meet API GL-5/MT-1 qualifications. The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below. In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases. This produces a thickening of the mineral oil at the contact point. This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and spalling fatigue. Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so. Before using a synthetic lubricant in heavy applications, the customer must check with the lubricant supplier on the issue of high-pressure lubricant applications.

Normal Oil Change Intervals: Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off-highway applications and 10,000 miles in on-highway applications. Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination. Judgment must be used to determine the required change intervals for extreme conditions.

Extended Oil Change Interval: Extended oil service may result when using synthetic lubricants.

Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a baseline. Wear metal analysis can provide useful information, but an axle should not be removed from service based solely on this analysis.

Vehicles, which are prone to high levels of ingested water in the axle, or water as a result of condensation, should not use extended drain intervals.

Friction Modifiers: Friction modifiers may be used with the lubricant to reduce Posi-Torq (limited slip) differential noise or liquid cooled brake noise. If friction modifiers re used, follow instructions on TSB 278E.

The use of aftermarket lubricant additives other than those specified is not recommended and may reduce the life of the axle and void the warranty!

°

C

°

F

SAE 140

80W140 / 85W140

SAE 90

80W90

75W90

75W

-40

-40

-30

-22

-20

-4

-10

14

0

32

10

50

20

68

30

88

40

104

Recommended Viscosity Grade Based on Prevailing Ambient Temperature

50

122

13

48T300 Drive Axle

Service Manual

BEARING HEATING AND FREEZING GUIDELINES

Bearings often must be cooled or heated to aid in assembly or removal. Since temperature extremes can cause permanent bearing metallurgical damage, it is important to take proper precautions and use correct methods when heating and cooling bearings.

Cups that are to be assembled in hubs or housings with a press fit may be shrunk in a deep freeze unit. Standard class bearings should not be cooled below -65° F (-54° C). In addition to cooling the bearing cup, in some instances it may be necessary to heat the housing.

To control temperature, is best to use a thermostat along with a freezer unit or a properly calibrated thermometer. If a suitable freezer or thermometer is not available, your Timken service representative can suggest liquid combinations that freeze the bearing cup at the optimal temperatures. Regardless of the method, check the cup’s final seating against the housing shoulder with feeler gauges.

Take extreme care that standard product bearings are never heated above

149° C [300° F]. If bearings are heated above this temperature, their metallurgical structure may soften, rendering them unsuitable for use.

There are a number of recommended methods for heating bearings. Electric ovens or electrically heated oil baths may be used, but only when accompanied by proper thermostatic control. If you use a hot plate to heat the oil, never rest bearings directly on the bottom of the pan. Instead, protect bearings from the heat source with a simple wire screen holder or similar device.

Use heat-resistant gloves to handle heated cones. Hold the hot cone solid against the cold shoulder on the shaft until the cone grabs on to the shaft. The hot cone will pull away from the cold shoulder unless it is held in position. Use .002 [.05 mm] feeler gages to make sure the cone is fully seated against the shoulder after the parts are cooled. Many loose bearing settings (excessive end play) are caused by an unseated cone working back against the shoulder in service.

14

48T300 Drive Axle

Service Manual

CLEANING AND INSPECTION

CLEANING

Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials.

CAUTION: Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when using solvent type cleaners.

BEARINGS

Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture free compressed air. Be careful to direct air stream across bearings to avoid spinning. Bearings may be rotated slowly by hand to facilitate the drying process.

HOUSINGS, COVERS AND CAPS

Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions, providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water.

Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.

CAUTION: Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners. Thoroughly dry all parts cleaned immediately by using moisture-free compressed air or soft lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil or lapping compound.

INSPECTION

The importance of careful and thorough inspection of all parts cannot be overstressed.

Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.

BEARINGS

Carefully inspect all rollers, cages and cups for wear, chipping or nicks to determine fitness of bearings for further use. Do not replace a bearing without replacing the mating cup or cone at the same time. After inspection, dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed.

OIL SEALS, GASKETS AND RETAINING RINGS

Replacement of spring loaded oil seals, gaskets, and snap rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a future time. Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing member should be handled carefully, particularly when being installed. Cutting, scratching or curling under lip of seal seriously impairs its efficiency. At reassembly, lubricate lips of oil seals with Multipurpose Lithium grease

“Grade 2”.

15

48T300 Drive Axle

Service Manual

CLEANING AND INSPECTION - CONT.

GEARS AND SHAFTS

If Magna-Flux or a dye penetrant process is available use process to check parts. Examine teeth and the ground/polished surfaces of all gears and shafts carefully for wear, pitting, chipping, nicks, cracks, or scoring. If gear teeth are cracked or show spots where case hardening is worn through, replace with new gear. Small nicks may be removed with suitable hone stone. Inspect shafts to make certain they are not sprung, bent or have twisted splines.

HOUSINGS, COVERS AND CAPS

Inspect housings and covers to be certain they are thoroughly cleaned and that mating surfaces, bearing bores, etc. are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures.

16

48T300 Drive Axle

Service Manual

AXLE REASSEMBLY

The reassembly instructions describe the procedure to be followed when reassembling and installing components of the axle. Instructions covering reassembly of opposite side are identical unless otherwise noted.

Important: Class 8.8, 10.9, 12.9, grade 5 and grade 8 fastening hardware has been used in the production of the axle assemblies covered in the manual. A table of proper torque values for the fastener classes above is provided within this manual. The class of hardware may be determined by the markings contained on the head of each capscrew.

Class 12.9 or grade 8 torque values needs to be used on all socket head capscrews used with this assembly. Torque values specified in the text of this manual are for class 8.8,

10.9, 12.9, grade 5 and grade 8 hardware were presently used in production. On all axles being overhauled, bolts and capscrews should be identified as described above and torque value chart consulted for correct torque.

THREAD LOCKING COMPOUND

Guidelines for application where to apply:

A. Bolts, capscrews, and studs (anchor end).

B. Nuts, apply compound to the male thread of the mating fastener.

C. Apply compound to coat the full length and circumference of thread engagement.

D. Remove excess compound from mating parts after fastener installation.

17

48T300 Drive Axle

Service Manual

PINION DEPTH SETTING PROCEDURE

The function of the pinion setting gauge is to measure the distance from the centerline of the differential bearing bores to the ground surface on the gear end of the pinion. This measurement when subtracted from the value etched on the ring gear will indicate the size of the shim pack required to position the pinion gear in proper relation to the ring gear.

On the outer diameter of the ring gear, a ring gear to pinion distance will be etched, add .4649 [11.808 mm] to it. (.4649 [11.808 mm] is half the thickness of the gauge bar).

Record this value. This value may be different on each ring and pinion set due to manufacturing variations.

Use a file and emery cloth to remove all burrs and nicks from machined bearing surfaces of carrier housing.

Paint bearing surfaces with bearing contact checking compound.

Insert an extension depth micrometer (Starrett #44B-6RC and extension #99347 7” [178 mm] or equivalent is recommended) into the guide bore of the micrometer arbor and slide clamps over base of micrometer. With the thumb screws reacting on base, secure micrometer.

IMPORTANT: The micrometer extension must pass freely through the micrometer bar guide bore and base of the micrometer must rest on the micrometer arbor when mounted.

Mount adapter discs on micrometer arbor and set in position in carrier housing. Exercise care to be sure that micrometer and extension do not contact any part of the carrier in this operation.

Apply pressure by hand and rotate adapter discs slightly to obtain a contact with bearing surfaces.

Remove checking gauge assembly and check for full bearing contact on bearing surfaces.

If contact is full and proper, again position checking gauge assembly in carrier and check distance to ground surface on pinion. Do not apply pressure to arbor or micrometer. Turn micrometer carefully and evenly until the flat tip of the micrometer extension contacts the ground surface of the pinion squarely. Subtract this reading from the value previously recorded and this equals the amount of shims to be added between the inner pinion bearing cup and the carrier housing.

EXAMPLE:

5.289 [134.341 mm] Value etched on ring gear.

+0.469 [011.913 mm] Constant (1/2 thickness of gauge bar).

5.758 [146.253 mm] Total

-5.728 [145.491 mm] Initial micrometer reading.

0.030 [ .762 mm] Add this value in shims under inner pinion bearing cup.

18

48T300 Drive Axle

Service Manual

WHEEL BEARING ADJUSTING INSTRUCTIONS

WITH POSI-STOP BRAKE

1. Before wheel bearing adjustment is made it is imperative all tapered bearing cones and cups be pressed to fully seated position. Do not attempt to seat cups and cones by tightening spindle nut against internal gear hub as this is not an effective method of seating the components and damage may occur.

2. Coat face of spindle nut, spindle threads and splines with Anti-Seize or Never-Seez.

3. Install spindle nut and tighten to 1200 LBF/FT [1627 Nm]. Shock internal gear hub with heavy bar while rotating wheel hub a minimum of 2 revolutions. Recheck nut torque, if nut moves re-torque to 1200 LBF/FT [1627 Nm] and repeat shocking and rotating. Repeat process until the spindle nut does not advance when tightened.

4. Loosen the spindle nut ¼ to ½ turn and shock the wheel hub until a slight amount of bearing end play is achieved and the wheel hub can rotate freely.

5. Using a strap, hoist and scale or torque wrench and adapter bar, determine the rolling torque of the wheel end with the bearings in a no load condition. Due to the imbalance of the hub assembly there will be a variation in rolling torque as the wheel hub is rotated.

Record the maximum rolling torque figure observed while the hub is being rotated. This figure will be the “No-Load” rolling torque.

6. The acceptable no-load value should be between 10–50 LBF/FT [14-68 Nm]. If higher than this open brake bleeder, rotate hub and shock brake to release brake. If brake doesn’t release apply 3 PSI [12 kPa] to cooling cavity of brake with bleeder open. Record no-load value.

NOTE:

The specifications given are for axles using new parts. For service on axles with used parts the procedure is the same except the minimum allowable rolling torque can be as low as 5

LBF/FT [7 Nm].

7. Tighten spindle nut to 600 LBF/FT [813 Nm]. Advance the nut until 3 pairs of holes in the lock plate line up with the holes in the internal gear hub.

8. Check wheel hub rolling torque, it must be within the specified range as listed below. If rolling torque is higher than specified reduce the nut torque to obtain an acceptable reading, but not less than 400 LBF/FT [542 Nm]. If spindle nut torque must be reduced below 400 LBF/FT [542 Nm] there is likely a concentricity or alignment issue in the hub assembly and it should be disassembled and inspected and reassembled as required.

9. If rolling torque is lower than specified increase spindle nut torque until preload is in specified range with lock plate holes aligned. Do not torque to more than 1400 LBF/FT

[1898 Nm]. Recheck rolling torque after rotating the wheel hub at least 5 times.

10. Install lock plate and screws and tighten to 35-40 LBF/FT [47-54 Nm].

Note: Bearing preload should be 50-80 LBF/FT [68-108 Nm] over no-load.

19

48T300 Drive Axle

Service Manual

FACE SEAL INSTALLATION INSTRUCTIONS

1 .

Clean wheel hub and brake housing bores with solvent prior to installation of the seal.

2 .

Keep original mated metal sealing rings as a set for wheel hub and brake cover

(DO NOT INTERMIX METAL RINGS).

3 .

All parts of seal should be free of grease, oil, dirt and scale.

4 .

Sealing rings must be handled with care. Lapped sealing faces must not be damaged, scratched or contaminated with dirt or grease.

5 .

When installing the rubber toric on the seal ring, make sure that it is uniformly seated on the retaining lip and is not twisted. Place the seal in the installation tool and locate this assembly squarely against the housing. Use sudden and even pressure against the tool to push the toric under the retaining lip of the housing cavity. Insure that the toric is uniformly captured under the housing cavity retaining lip and is not twisted or pinched. The seal ring face should be parallel to the housing within .040 [1.0 mm].

6 .

After installing the seal halves into the wheel hub and brake housing, wipe both metal sealing surfaces clean with lint free cloth. Then apply a coat of clean MS8 oil to the metal seal faces with a lint free applicator. Oil must not wet surfaces other than sealing faces.

20

48T300 Drive Axle

Service Manual

POSI-STOP BRAKE PRESSURE TEST INSTRUCTIONS

1. Air Pressure Decay Test and Criteria

A. After completing assembly and with bleeder plugged, apply 12 PSI [83 kPa] air pressure to the brake fluid actuation port. Shut off air at inlet to hold pressure on brake.

B. Let pressure stabilize for 30 seconds. This is to compensate for temperature change, piston movement and seating of seal lips.

C. Re-pressure to 12 PSI [83 kPa] if required and hold for 15 seconds with no pressure drop.

D. Repeat re-pressuring until 12 PSI [83 kPa] holds for 15 seconds minimum, but not over 3 repressurings.

E. If after 3 re-pressurings brake will still not hold pressure, tear down and determine cause of leak, rebuild and retest.

2. Air and Hydraulic Pressure Test

A. After completing assembly, with bleeder plugged apply 100 PSI [689 kPa] air pressure to the brake fluid actuation port. Shut off air at inlet to hold pressure on brake. Brake should maintain pressure for 30 seconds without drop.

B. Apply 1500 +50/-00 PSI [10342 +344/-000 kPa] hydraulic pressure using mineral oil to brake actuation port, shut off pressure at inlet to hold pressure on brake. Inspect to insure that pressure plate has moved against housing stop and that friction discs are released and free. Maintain pressure for 30 seconds minimum without drop. Repeat twice. If brake will not maintain pressure, tear down and determine cause of leak, rebuild and retest.

21

48T300 Drive Axle

Service Manual

AXLE PRESSURE TEST INSTRUCTIONS

1.

If brake assembly is disassembled or partially disassembled, the pressure apply fluid actuation test must be performed per the Brake Pressure Test Instructions.

2.

If brake assembly is not disassembled or partially disassembled before mounting to axle, no pressure apply fluid check is required.

Pressure test axle as follows:

A.

Remove drain plugs from both brakes.

B.

Apply 12 PSI [83 kPa] air pressure to complete axle (Normally thru axle housing breather hole) and shut air off at inlet to lock pressure on axle.

C.

Axle must hold 12 PSI [83 kPa] for 15 seconds with no drop in pressure.

D.

If leaks occur, determine cause, rebuild and retest (see (1) above also).

E.

If no leaks occur, make sure cooling ports are plugged , apply 12 PSI [83 kPa] air pressure to drain port of each brake, shut off air at inlet to lock pressure on brake cavity.

F.

Each brake cavity must hold 12 PSI [83 kPa] for 15 seconds with no drop in pressure.

G.

If leaks occur, determine cause, rebuild and retest starting at (A)

(see (1) above also).

22

48T300 Drive Axle

Service Manual

GEAR TOOTH CONTACT CHART - LH

23

48T300 Drive Axle

Service Manual

GEAR TOOTH CONTACT CHART - RH

24

48T300 Drive Axle

Service Manual

Size

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

9/16-12

9/16-18

5/8-11

5/8-18

3/4-10

3/4-16

FASTENER TORQUE CHART

STANDARD FASTENERS

Lubricated and Plated Bolts, CapScrews, and Studs

Grade 5 Grade 8

3 Radial Dashes On Bolt Head

LBF/FT

10

[Nm]

14

11

16

15

22

20

25

27

34

39 29

41

45

63

70

56

61

85

90

100

124

95

122

136

168

141

220

245

191

298

332

6 Radial Dashes On Bolt Head

LBF/FT

11

[Nm]

15

13

30

18

41

32

36

43

49

56 41

57

64

88

99

77

87

119

127

141

175

198

134

172

191

237

310

347

268

420

470

M12

M14

M16

M18

M20

M22

M24

Size

M4

M5

M6

M8

M10

METRIC FASTENERS

Lubricated and Plated Bolts, CapScrews, and Studs

Class 8.8

8.8 on Bolt Head

Class 10.9

10.9 on Bolt Head

Class 12.9

12.9 on Bolt Head

LBF/FT

2.2

4.4

7.4

18

36

63

100

155

221

313

428

538

[Nm]

3

5.9

10

25

49

85

135

210

300

425

580

730

LBF/FT

3.2

6.4

11

26

51

92

147

229

317

450

605

774

[Nm]

4.4

8.7

15

36

72

125

200

310

430

610

820

1050

LBF/FT

7.4

7.4

13

32

62

107

173

269

369

524

708

900

[Nm]

10

10

18

43

84

145

235

365

500

710

960

1220

25

48T300 Drive Axle

Service Manual

PLUG AND ELASTIC STOP NUT TORQUE CHARTS

Size

5/16-24

3/8-24

7/16-20

1/2-20

9/16-18

3/4-16

7/8-14

1 1/16-12

1 3/16-12

1 5/16-12

1 5/8-12

1 7/8-12

O-RING PLUGS

P/N

24K-1

24K-2

24K-3

24K-4

24K-5

24K-6

24K-7

24K-8

24K-9

24K-10

24K-11

24K-12

LBF/FT

5

8

10

13

15

25

35

50

60

75

85

85

[Nm]

7

11

14

18

20

34

47

68

81

102

115

115

PIPE PLUGS

Size (NPTF) LBF/FT

1/16-27

7

1/8-27

1/4-18

3/8-18

10

20

30

1/2-14

3/4-14

35

45

1-11 1/2

55

1 1/4-11 1/2

65

[Nm]

9

14

27

41

47

61

75

88

ELASTIC STOP NUTS

Size

1-20

1 1/4-18

1 1/2-18

1 3/4-12

LBF/FT

200

250

350

450

[Nm]

270

340

475

610

26

48T300 Drive Axle

Service Manual

Planetary Removal

DISASSEMBLY

Figure 1

Drain oil from wheel ends, brakes, and center section.

Figure 4

Install chain clevis.

Figure 2

Remove (3) planet carrier screws.

Figure 5

Attach chain.

Figure 3

Pry planet carrier out of wheel hub enough to install chain clevis.

CAUTION: Use care not to over extend planet carrier as serious injury can result.

27

Figure 6

Remove planet carrier from hub.

48T300 Drive Axle

Service Manual

Figure 7

Remove sun gear.

Figure 10

Remove (6) lock plate screws.

Figure 8

Remove planet carrier o-ring.

Axle Shaft and Hub Removal

Figure 11

Remove spindle nut lock plate.

Figure 9

Remove axle shaft.

28

Figure 12

Remove spindle nut.

48T300 Drive Axle

Service Manual

Face Seal Removal

Figure 13

Install lifting device

Refer to tool drawing on page 99.

Figure 16

Carefully pry face seal from hub. Avoid making contact with seal bore or sealing surfaces that could cause damage and leaks.

Figure 14

Install (2) screws with flat washers at 4:00 & 8:00 positions as shown to retain internal gear.

Figure 17

Remove face seal from hub.

Figure 15

Remove hub assembly.

29

Figure 18

Remove face seal from brake housing.

48T300 Drive Axle

Service Manual

Brake and Spindle Removal

Figure 19

Remove (1) brake cover attaching screw at 12:00 position.

Figure 22

Loosen top mounting screw.

An 18 to 1 torque multiplier is shown.

Figure 20

Install lifting device.

Refer to tool drawing on page 99.

Figure 23

Remove spindle mounting screw as shown.

Figure 21

Attach chain. Approximate balance point is shown.

30

Figure 24

Install alignment pin.

48T300 Drive Axle

Service Manual

Figure 25

Threaded end of pin must engage threads in axle housing a minimum of 1.5 times pin diameter or 2.0 [50.8 mm].

Figure 28

Carefully remove brake assembly.

Figure 26

Remove remaining (12) brake and spindle mounting screws.

Figure 29

Remove brake to spindle seal ring.

Figure 27

Remove spindle retaining ring.

31

Figure 30

Remove spindle.

CAUTION:

Spindle is heavy and weighted off center.

IMPORTANT:

Do not clean/chase axle housing threads using a tap.

48T300 Drive Axle

Service Manual

Figure 31

Remove spindle pilot seal ring.

Figure 34

Remove output flange dust shield.

NOTE: Remove only if replacement is required.

Figure 32

Remove spindle to axle housing seal ring.

Output Flange and Bearing Removal

Figure 35

Pry bearing and oil seal retainer away from axle housing and remove. Using appropriate puller remove outer roller bearing, bearing spacer and inner roller bearing.

Figure 33

Remove cotter pin, flange nut, washer, output flange,

and (7) bearing & oil seal retainer nuts and lockwashers.

32

Figure 36

Remove bearing and oil seal retainer o-ring.

48T300 Drive Axle

Service Manual

Figure 37

Remove oil seal as shown or drive out from back side with a punch.

Differential and Carrier Assembly Removal

Figure 40

Remove (4) tapered dowels.

Figure 38

Remove (3) 12 point differential mounting nuts and washers.

Figure 41

Remove (2) carrier cover screws on horizontal center line of pinion shaft.

Figure 39

Remove (11) differential mounting nuts and washers.

33

Figure 42

Install lifting chain with (2) screws and flat washers.

NOTE: Length of screws must be the length of the screws removed plus the thickness of the chain used to assure adequate engagement of threads.

48T300 Drive Axle

Service Manual

Figure 43

Remove differential and carrier assembly.

Planetary Disassembly

Figure 46

Remove (4) gear and bearing assemblies.

Inspect bearing contact surfaces for wear and damage.

Figure 44

Remove (4) retaining rings.

Figure 47

Remove thrust washer as shown.

Clean and inspect all components.

Repair or replace components as required.

Hub Disassembly

Figure 45

OPTIONAL: Apply heat to inner bearing race to facilitate removal. Refer to bearing heating and freezing guidelines on page 14.

34

Figure 48

Block hub to secure as shown. Remove lifting device.

48T300 Drive Axle

Service Manual

Figure 49

Remove (2) screws and flat washers.

Figure 52

OPTIONAL: Apply heat to inner race of bearing cone to facilitate removal. Refer to bearing heating and freezing guidelines on page 14. NOTES: If using heat immediately proceed to step in figure 53 before bearing cools.

NOTE: Internal ring gear assembly not as shown.

Figure 50

Carefully remove internal ring gear and hub assembly from hub.

CAUTION: Ring gear assembly is heavy.

Figure 53

Remove bearing cone using punch as shown.

NOTE: Internal ring gear assembly not as shown.

Refer to exploded view and parts

description on pages 5 and 6 for this procedure.

Figure 51

Remove internal ring gear snap ring (Item 28).

Separate internal gear hub (Item 27) from internal ring gear (Item 26).

35

Figure 54

Remove hub seal as shown or drive bearing cone and seal out from other side.

48T300 Drive Axle

Service Manual

Figure 55

Remove hub seal and bearing cone.

Figure 56

Remove outer wheel bearing cup.

Figure 57

Remove inner bearing cup.

36

48T300 Drive Axle

Service Manual

Posi-Stop Brake Disassembly

Figure 58

Remove (4) warning sticker cover screws.

Figure 61

Remove (2) pressure port plugs.

Brake Cover Removal

Figure 59

Remove (2) warning sticker covers. Note Warning!

Figure 60

Note warning cast into brake cover.

37

Figure 62

This disassembly procedure is tedious and time consuming. Due to the potential for injury and damage any shortcuts should be avoided. A spring compression tool drawing and instructions are included on page 93. It is recommended the compression tool be used to disassemble and reassemble the brake. IMPORTANT!! If the brake spring compression tool is not going to be used, the following procedure must be followed to avoid personal injury and component damage.

CAUTION: The brake cover is under 72,000 psi (pounds/square inch) of pressure created by the brake apply springs.

It is recommended that the capscrew heads be numbered to assist in following the loosening/ tightening sequence. Refer to figure 63. In a crossing or star pattern loosen the (24) brake cover capscrews turning no more than one quarter

(1/4) turn at a time in sequence. Continue this process until all pressure on the cover has been relieved.

48T300 Drive Axle

Service Manual

Discs, Pressure Ring and Spring Removal

Figure 63

After all spring force has been relieved from cover remove the (24) cover screws and washers.

Figure 66

Remove brake friction and reaction discs. NOTE: If discs are to be reused they need to be reinstalled in the exact order and direction in which they were removed.

Figure 64

Install (2) eye bolts to assist in handling the brake cover in opposite warning plate holes.

Figure 67

Remove brake piston pressure ring.

Figure 65

Remove brake cover.

38

Figure 68

Remove brake springs. NOTE: Inner and outer springs are matched sets and must remain together.

As each set is removed it is recommended that they be wired together to prevent mixing sets.

48T300 Drive Axle

Service Manual

Piston Removal

Figure 69

Remove brake cover seal ring.

Wear Indicator Pin Removal

Figure 72

Place brake cover on flat surface face down. Install (3) screws and flat washers in the brake piston puller holes.

CAUTION: Brake cover is heavy and can cause injury and damage.

Figure 70

Tap out brake wear indicator pin.

Figure 73

Piston with puller screws and washers installed.

Figure 71

Remove brake wear indicator pin.

39

Figure 74

Using a pry bar, evenly pry piston out of the brake cover until it is no longer in contact with the piston seals.

48T300 Drive Axle

Service Manual

Figure 75

Piston pulled out of seals.

Piston can be removed by hand at this point.

Figure 78

Remove inner piston seal assembly.

Figure 76

Remove brake piston.

Figure 79

Remove (2) pressure port sealing rings.

Figure 77

Remove outer piston seal assembly.

40

Figure 80

Remove pressure ring seal ring.

48T300 Drive Axle

Service Manual

Figure 81

Remove (2) brake wear indicator pin o-rings.

Figure 82

Remove brake wear indicator pin retaining ring.

NOTE: Not necessary to remove unless replacement is required.

Clean and inspect all components.

Repair or replace components as required.

41

48T300 Drive Axle

Service Manual

Differential and Carrier Disassembly

Input Flange Removal

Figure 83

Remove input flange nut cotter pin.

Figure 86

Remove input flange dust shield.

NOTE: Remove only if replacement is required.

Figure 84

Remove input flange nut and washer.

Figure 87

Loosen thrust screw lock nut.

Figure 85

Remove input flange.

42

Figure 88

Remove thrust screw.

48T300 Drive Axle

Service Manual

Differential and Ring Gear Removal

Figure 89

Mark carrier and caps to identify for reassembly.

Figure 92

Remove carrier caps.

Figure 90

Remove (2) differential adjusting nut lock screws and lock washers.

Figure 93

Remove differential adjusting nuts.

Figure 91

Remove (4) carrier cap nuts and washers.

43

Figure 94

Remove bearing cups.

48T300 Drive Axle

Service Manual

Figure 95

Remove differential assembly.

Input & Drop Gear Shaft Removal

Figure 98

Remove cover.

Figure 96

Remove (11) carrier cover screws and lock washers.

Figure 99

Remove input shaft oil seal from carrier cover.

Figure 97

Carefully pry carrier cover from carrier housing.

44

Figure 100

Remove (8) input shaft outer bearing retainer screws and lock washers.

48T300 Drive Axle

Service Manual

Figure 101

Carefully pry outer bearing retainer from carrier.

Figure 104

Remove remaining (5) drop gear access cover screws, lock washers and cover.

Figure 102

Remove outer bearing retainer and shims.

Figure 105

Reinstall input flange nut to protect threads from damage.

Figure 103

Remove (2) top corner drop gear access cover screws and install alignment pins. NOTE: Alignment pins can be made by removing heads from bolts.

45

Figure 106

Tap end of input and drop gear shaft to release pressure on the bearing retaining snap ring.

48T300 Drive Axle

Service Manual

Figure 107

Remove bearing retaining snap ring.

NOTE: Input and drop gear shaft not as shown.

Figure 110

Remove input and drop gear shaft outer bearing cone.

NOTE: Input and drop gear shaft not as shown.

Figure 108

Drive input and drop gear shaft out of inner bearing cone.

The outer input shaft bearing cup will also be pushed out of the carrier during this procedure.

NOTE: Input and drop gear shaft not as shown.

Figure 111

Remove input drop gear, bearing and snap ring washer.

Pinion and Drop Gear Removal

Figure 109

Remove input and drop gear shaft.

NOTE: Input and drop gear shaft not as shown.

46

Figure 112

Remove pinion nut cotter pin.

48T300 Drive Axle

Service Manual

Figure 113

Remove pinion nut and washer.

Figure 116

Remove outer pinion bearing cone and spacer.

Figure 114

Install pinion removal tool as shown.

Refer to tool drawing on page 101.

OPTIONAL: Reinstall pinion nut to protect threads and carefully drive pinion out of bearing.

Figure 117

Remove pinion.

Figure 115

Press pinion out of outer pinion bearing cone.

47

Figure 118

Remove inner pinion bearing cone.

48T300 Drive Axle

Service Manual

Figure 119

Remove pinion drop gear.

Figure 122

Inner pinion bearing cup removed with shims.

Figure 120

Remove outer pinion bearing cup.

Figure 123

Remove inner input and drop gear shaft bearing cup.

Ring Gear Removal

Figure 121

Remove inner pinion bearing cup.

48

Figure 124

Remove (12) ring gear nuts.

48T300 Drive Axle

Service Manual

Figure 125

Remove (12) ring gear screws using a punch as shown. NOTE: Use energy absorbing material, like the wood blocks shown, to protect the ring gear teeth. The ring gear should fall onto this material after a number of the screws are removed. If it does not, tap gear with a soft mallet.

Figure 128

OPTIONAL: To facilitate removal of differential body screws apply heat to release thread locking compound.

Be careful not to overheat or discolor unit.

Figure 126

Ring gear after dropping onto protective wood blocks.

Differential Disassembly

Figure 129

Remove (12) differential body screws and washers.

Figure 127

Mark differential case halves to identify for reassembly.

49

Figure 130

Separate differential halves.

48T300 Drive Axle

Service Manual

Figure 131

Remove inner and outer differential clutch discs.

Figure 134

Remove differential pinion thrust washers and outer bearing spacers.

Figure 132

Remove side gear.

Figure 135

Remove differential pinion gears, needle rollers, inner and center bearing spacers.

Figure 133

Remove differential spider, pinion gear assemblies and thrust washers.

50

Figure 136

Remove side gear from differential body flanged half.

48T300 Drive Axle

Service Manual

Figure 137

Remove inner and outer differential clutch discs from differential body flanged half.

Figure 138

OPTIONAL: Apply heat to facilitate removal of plain half bearing cone.

Figure 139

Remove plain half bearing cone. Repeat steps in

figures 138 & 139 to remove flanged half bearing cone.

Clean and inspect all components.

Repair or replace components as required.

51

48T300 Drive Axle

Service Manual

Planetary Reassembly

REASSEMBLY

Figure 140

Locate thrust washer chamfer as shown.

Figure 143

Heat gear and bearing assembly to aid assembly.

Install with the bearing radius down. Refer to bearing heating and freezing guidelines on page 14.

Figure 141

Using appropriate driver, install washer in planet carrier.

Figure 144

Install retaining ring.

Figure 142

Identify large radius on bearing race as shown.

Gear and bearing assembly must be assembled with radius facing towards planet carrier.

52

Figure 145

Repeat steps in figures 142-144 for remaining (3) assemblies.

48T300 Drive Axle

Service Manual

Hub Reassembly

Figure 146

Install inner and outer bearing cups. Tips for installing cups can be found in bearing heating and freezing guidelines on page 14.

Figure 149

Lubricate inner cone with axle lubricant and install.

Figure 147

Using a .002” feeler gage check that bearing cups are seated against the shoulder. When cup is seated, feeler gage should not fit between cup and hub shoulder. Check in several locations.

Figure 150

Apply continuous coat of Loctite 262 or equivalent to outside diameter of hub seal.

Insure entire surface is covered.

CAUTION: Do not over apply.

Figure 148

Lubricate bearing cup with axle lubricant.

53

Figure 151

Use seal driver to install seal.

Refer to tool drawing on page 102.

48T300 Drive Axle

Service Manual

Internal Ring Gear and Hub

Assembly and Installation

Refer to exploded view and parts

description on pages 5 and 6 for this procedure.

Figure 152

Install internal gear hub (Item 27) in internal ring gear (Item 26).

Install internal ring gear snap ring (Item 28).

.

Figure 155

Install internal ring gear in hub.

NOTE: Internal ring gear and hub assembly not as shown.

Figure 153

Heat inner bearing cone and install on internal gear hub.

Refer to bearing heating and freezing guidelines on page 14.

NOTE: Internal ring gear and hub assembly not as shown.

Figure 156

Install (2) screws with large flat washers as shown.

Lightly tighten screws until washers contact hub.

Figure 154

Lubricate inner bearing cone with axle lubricant.

NOTE: Internal ring gear and hub assembly not as shown.

54

Figure 157

Install lifting device.

Refer to tool drawing on page 99.

48T300 Drive Axle

Service Manual

Posi-Stop Brake Reassembly

Figure 158

Clean cured thread locking compound from holes with a .625-11 UNRC-2A tap. Use compressed air to remove residue from holes. Use appropriate eye protection when using compressed air.

Figure 161

Install (2) wear indicator pin o-rings and lubricate.

Figure 159

Position brake housing on blocks as shown to allow clearance for the wear indicator pin. Pin will protrude through bottom of housing.

Wear Indicator Pin Installation

Figure 162

Install wear indicator pin in housing.

Pressure Ring and Spring Installation

Figure 160

Install wear indicator pin retaining ring.

55

Figure 163

Lubricate pressure ring o-ring sealing surface with grease.

48T300 Drive Axle

Service Manual

Figure 164

Install brake spring sets.

Figure 167

Set pressure ring into position. A lifting device similar to the one shown can ease installation.

Refer to tool drawing on page 98.

Brake Disc Installation

Figure 165

Lubricate brake cover seal ring with grease and install.

Figure 168

Install reaction disc.

Figure 166

Lubricate seal ring with grease and install on pressure ring.

Figure 169

Identify the rounded edges on teeth of friction discs.

Rounded edges should be installed facing “UP”.

56

48T300 Drive Axle

Service Manual

Piston Installation

Figure 170

Install friction disc. Alternately install the remaining reaction and friction discs. NOTE: Align the friction disc oil grooves (missing teeth) with the previously installed friction disc. Alignment of friction disc teeth at this time will ease spline engagement during hub installation.

Figure 173

Install outer piston seal assembly.

Figure 171

Line up the reaction disc teeth with the internal teeth in brake housing.

Figure 174

Install inner piston seal assembly. NOTE: Use caution not to over stretch the inner o-ring and seal ring.

Figure 172

Install (2) alignment pins in brake housing

180° apart. NOTE: Alignment pins can be made by using bolts with heads cut off.

57

Figure 175

Lightly lubricate inner and outer piston seals and piston with grease, install piston in brake cover.

48T300 Drive Axle

Service Manual

Figure 176

Evenly press piston into brake cover until it bottoms out.

“C” clamps can be used, as shown, to ease this process.

Cover Installation

Figure 179

Remove (2) alignment pins and install

(24) brake cover screws and washers.

NOTE: Run screws down only “Finger Tight”.

Figure 177

Install (2) pressure port seal rings. NOTE: Use grease to retain seal rings in grooves during handling and assembly.

Figure 180

Mark screws with numbers from

1-24 in a criss crossing pattern.

Figure 178

Mark location of pressure ports on brake cover and housing. Align ports and install cover on alignment pins.

58

Figure 181

Carefully recheck alignment of reaction disc teeth and teeth in the brake housing.

IMPORTANT: This is a critical step. If the teeth are not properly aligned they will not enter the brake housing without damage as the springs are compressed.

48T300 Drive Axle

Service Manual

Figure 182

Tighten the (24) brake outlet cover screws in a criss crossing pattern by turning each screw NO MORE THAN

1/4 TURN. As springs are compressed check alignment of reaction disc teeth as they enter the brake housing.

When cover contacts brake housing the screws should be tightened to 175-190 LBF/FT [240-260 Nm].

Figure 185

Hydraulic pressure test brake.

Refer to pressure test instructions on page 21.

Figure 183

Install (2) pressure port plugs.

Tighten to 84-120 LBF/IN [10-14 Nm].

Figure 186

One at a time remove the (24) brake cover screws.

Apply Loctite 262 or equivalent to the threads, reinstall and tighten to 175-190 LBF/FT [240-260 Nm].

IMPORTANT: Do not remove more than one screw at a time.

Figure 184

Air pressure test.

Refer to pressure test instructions on page 21.

59

Figure 187

Install (2) warning sticker covers with (4) screws and tighten to 215-240 LBF/IN [24-27 Nm].

48T300 Drive Axle

Service Manual

Differential and Carrier Reassembly

Figure 188

Using appropriate driver install pinion shaft outer bearing cup.

Figure 191

Using appropriate driver install pinion shaft inner bearing cup.

Figure 189

Using appropriate driver install input shaft inner bearing cup.

Calculating and Installing Pinion Shims

Figure 192

Using a .002” feeler gage check to be sure inner and outer bearing cups are seated in bores. When cups are properly seated the feeler gage should not fit between the cups or shims and carrier housing shoulder. Check several locations around the cup diameter. Refer to bearing heating and freezing guidelines on page 14.

Figure 190

Install the original or same thickness inner pinion bearing cup shim pack if reinstalling the original ring and pinion set. If installing a new ring and pinion set compare the etched numbers on the ring gears and adjust the shim pack accordingly. The total length of the etched number and shim thickness of new ring and pinion should be the same as the old ring and pinion number and shim pack. Refer to detailed depth setting procedure on page 18.

60

Figure 193

Lubricate inner pinion bearing cup with axle lubricant.

48T300 Drive Axle

Service Manual

Figure 194

Position pinion drop gear in housing aligning hole in gear with bore in housing.

Pinion Gear Installation and Preload

Figure 197

Install pinion in housing and drop gear.

Figure 195

Heat and install pinion shaft inner bearing cone. Refer to bearing heating and freezing guidelines on page 14.

Figure 198

Secure pinion in position with a holding device similar to one shown.

Figure 196

Install original pinion shaft inner bearing spacer if ring and pinion or drop gear was not replaced. See service parts list for spacer and shim kit to be used with new ring and pinion and/or drop gear. Follow the instructions supplied with the kit for proper usage and assembly of spacer and shim kit.

61

Figure 199

Install original pinion shaft outer bearing spacer if ring and pinion or drop gear was not replaced. See service parts list for spacer and shim kit to be used with new ring and pinion and/or drop gear. Follow the instructions supplied with the kit for proper usage and assembly of spacer and shim kit.

48T300 Drive Axle

Service Manual

Figure 200

Lubricate outer pinion bearing cup with axle lubricant.

Figure 203

Tighten pinion nut to *525-560 LBF/FT [712-759 Nm].

Use pinion locking tool shown in figure 204 or equivalent to hold pinion from turning. *NOTE: If original bearing spacer has been replaced with the pinion bearing spacer and shim kit, apply Loctite 262 or equivalent to the pinion nut threads and tighten to

700-750 LBF/FT [950-1017 Nm].

Figure 201

Using appropriate driver, or by heating, install pinion shaft outer bearing cone.

Figure 204

Pinion locking tool. Refer to tool drawing on page 100.

Figure 202

Install pinion nut and washer.

62

Figure 205

Tap end of pinion several times with a soft mallet to seat bearings.

48T300 Drive Axle

Service Manual

Figure 206

Tap carrier housing several times with a soft mallet to seat bearings. Refer to figure 203 and recheck pinion bearing nut torque.

Figure 209

Install pinion nut cotter pin and bend ends as shown.

Input and Drop Gear Shaft Installation

Figure 207

Remove pinion holding device.

Figure 210

Heat input shaft inner bearing cone and place into inner bearing cup in housing. IMPORTANT: Immediately proceed to steps in figures 211 & 212 before bearing cools.

Figure 208

Check pinion bearing preload with a dial torque wrench. Reading should be 5-30 LBF/IN [.6-3.4 Nm].

If reading is not within specification the original bearing spacer will need to be replaced with a pinion bearing spacer and shim kit. If the spacer and shim kit has already been installed adjustments to the shim pack are required. See service parts list for spacer and shim kit identification. Follow instructions supplied with the kit for proper usage and assembly.

Repeat disassembly steps in figures 113-117 and reassembly steps in figures 196-208.

63

Figure 211

Heat and position input shaft drop gear in housing.

IMPORTANT: Immediately proceed to step in

figure 212 before drop gear and bearing cool.

48T300 Drive Axle

Service Manual

Figure 212

Install input shaft into drop gear and inner bearing cone.

Figure 215

Drive input and drop gear shaft forward to remove all end clearance between snap ring, snap ring washer, bearing cone and to insure that bearing cup is seated in bore. NOTE: Be sure to protect end of shaft and threads from being damaged.

IMPORTANT:

This is a very critical procedure.

If all end clearance is not removed

the bearing preload will be lost after machine is in operation.

Figure 213

Install input shaft snap ring washer.

Figure 214

Install input shaft bearing retaining snap ring.

64

Figure 216

Heat input shaft outer bearing cone and install.

48T300 Drive Axle

Service Manual

Figure 217

Position input outer bearing cup over shaft.

Figure 220

Position bearing retainer shims on alignment pin.

NOTE: It is a good practice to start out with the same or same thickness shim pack that was removed.

Figure 218

Using appropriate driver install input shaft outer bearing cup.

Figure 221

Position bearing retainer on alignment pin.

Figure 219

Install (1) alignment pin in bolt circle around input shaft bearing. NOTE: Alignment pin can be made by removing the head from a bolt.

65

Figure 222

Install (4) input bearing retainer screws and lock washers in every other hole and tighten to

65-40 LBF/FT [88-95 Nm].

48T300 Drive Axle

Service Manual

Setting Input and Drop Gear Shaft End Play

Figure 223

STEP 1 Using a dial indicator and pry bar as shown, pry between bottom of drop gear and housing to measure input shaft end play and record value. If no end play exists add shims to obtain approximately

.004-.006” [.102-.152mm] end play.

STEP 2 Using a dial type torque wrench measure the no-load rolling torque of the input shaft assembly and record value.

STEP 3 Calculate shim pack thickness by subtracting the amount of recorded end play from step 1 less an additional .002” [0.050mm] from the total shim pack thickness.

EXAMPLE:

0.080 " [2.032mm] - Initial Shim Pack Thickness

-0.004 " -[0.100mm] - End Clearance From Step 1

-0.002 " -[0.050mm] - Bearing Preload

0.074 " [1.882mm] - Desired Shim Pack Thickness

STEP 4 Remove input bearing retainer screws, bearing retainer and shims. Install desired shim pack as determined in step 3 and reinstall bearing retainer. Reference figures 220-222.

STEP 5 Using a dial type torque wrench measure the rolling torque of the input shaft assembly and record value.

STEP 6 Subtract value in step 2 from value in step 5. The correct result should be 27-41 LBF/IN [3-5Nm].

If the result is not within this range repeat steps 4-6 adding or subtracting .002” [0.050mm] thickness shims until the desired rolling torque is obtained.

EXAMPLE:

47 LBF/IN [5.3Nm] - Value from step 5

-17 LBF/IN -[1.9Nm] - No-load value from step 2

30 LBF/IN [3.4Nm] - Must be within 27-41 LBF/IN [3-5Nm]

66

48T300 Drive Axle

Service Manual

Figure 224

Remove (4) retainer screws and lock washers.

Apply Loctite 262 or equivalent to (8) input shaft bearing retainer screws, assemble with lock washers and tighten to 65-70 LBF/FT [88-95 Nm]. Remove input flange nut.

Differential Body Assembly

Figure 227

Install (4) differential outer clutch discs into differential flanged half.

Figure 225

Clean cured thread locking compound from differential plain half screw holes with a .625-11 UNC-3B tap and clean holes of any remaining residue.

Figure 228

Install (3) differential inner clutch discs onto side gear.

Figure 226

Heat and install bearing cones on differential body halves.

67

Figure 229

Install side gear with clutch discs into differential body flanged half.

48T300 Drive Axle

Service Manual

Figure 230

Apply a heavy coat of grease or petroleum jelly to the inside diameter of differential pinion gear. The grease is used to hold needle rollers in position in following steps.

Figure 233

Load second row of (29) needle rollers.

Figure 231

Load (29) needle rollers into one end of differential pinion gear bore.

Figure 234

Install inner and outer bearing spacers and install gear onto spider. NOTE: See figure 235 for proper spacer usage and positioning.

INNER

CENTER

OUTER

Figure 232

Install center bearing spacer.

68

Figure 235

Proper bearing spacer usage and positioning.

48T300 Drive Axle

Service Manual

Figure 236

Lubricate and install differential thrust washer.

Repeat steps in figures 230-236 for remaining (3) differential pinion gears.

Figure 239

Align tangs on (4) pinion thrust washers with counter bore in differential body as shown.

Figure 237

Lubricate differential side gear with axle lubricant.

Figure 240

Lubricate pinion gear teeth with axle lubricant.

Figure 238

Set the differential spider with gears in the differential body bores and side gear teeth.

69

Figure 241

Set side gear onto differential pinion gears.

48T300 Drive Axle

Service Manual

Figure 242

Install (3) inner clutch discs on side gear.

Figure 245

Place the differential body plain half on the flanged half.

IMPORTANT: Line up the identification marks made during disassembly.

Figure 243

Install (4) outer clutch discs on side gear aligning outer tangs of discs with each other.

Figure 246

Apply Loctite 262 or equivalent to (12) differential body screws and install with washers.

Figure 244

Proper clutch disc stack up and alignment.

70

Figure 247

Tighten differential body screws to

175-190 LBF/FT [237-258 Nm].

48T300 Drive Axle

Service Manual

Ring Gear Installation

Figure 248

Use a hone stone or file to remove nicks or burrs from ring gear mounting face. NOTE: Be sure to remove all abrasive residue.

Figure 251

Align holes in ring gear with holes in differential body flange. Insert (12) ring gear mounting screws.

Figure 249

Use a hone stone or file to remove nicks or burrs from ring gear mounting face. NOTE: Be sure to remove all abrasive residue.

Figure 252

Tap (12) ring gear mounting screws into fully seated position. IMPORTANT: Correct alignment of screw heads shown in figure 253.

Figure 250

Place ring gear on differential flanged half.

71

Figure 253

Proper alignment of ring gear mounting screw heads with inside diameter of ring gear counter bore.

48T300 Drive Axle

Service Manual

Figure 254

Apply Loctite 262 or equivalent to ring gear mounting screws.

Figure 257

Lubricate (2) differential bearing cones with axle lubricant.

Figure 255

Install (12) ring gear mounting screw nuts and tighten to 175-190 LBF/FT [240-260 Nm].

Differential Body and

Ring Gear Installation

Figure 258

Install (2) differential bearing cups.

Figure 256

Set differential assembly into carrier.

72

Figure 259

Install (2) differential adjusting nuts.

48T300 Drive Axle

Service Manual

Setting Ring Gear Backlash

Figure 260

Tighten both adjusting nuts to take up all clearance in the differential bearings. Rock ring gear back and forth during this process to check for backlash.

Carrier Cap Installation

Figure 263

Using a dial indicator as shown check ring gear and pinion backlash. Backlash specification is .010-.015

[.250-.380 mm]. Adjustment is made by loosening adjusting nut on one side and tightening opposite nut a corresponding amount until the correct backlash is achieved. After obtaining correct backlash recheck tightness of adjusting nuts to assure that all clearance has been removed from differential bearings.

Figure 261

Install both carrier caps.

Line up identification marks made during disassembly.

Figure 264

Remove (4) cap nuts, apply Loctite 262 or equivalent and reinstall.

Figure 262

Install (4) carrier cap nuts and washers.

Tighten only enough to seat caps at this time.

73

Figure 265

Tighten cap nuts to 475-525 LBF/FT [645-710 Nm].

48T300 Drive Axle

Service Manual

Figure 266

Apply Loctite 262 or equivalent to

(2) differential adjusting nut lock screws.

Figure 269

Install (2) alignment pins in top corner holes.

Figure 267

Install (2) differential adjusting nut lock screws and washers. Tighten to 15-18 LBF/FT [20-24 Nm].

NOTE: Select the screw hole that does not cause the screw to interfere with the adjusting nut lugs.

Drop Gear Cover Installation

Figure 270

Install access cover on alignment pins. Apply Loctite

262 or equivalent to (6) cover screws and install with lock washers. Remove (2) alignment pins and install remaining screws and lock washers.

Figure 268

Apply a continuous .06 [1.5 mm] diameter bead of

RTV sealant to drop gear access cover mounting surface.

74

Figure 271

Tighten cover screws to 25-28 LBF/FT [34-38 Nm].

48T300 Drive Axle

Service Manual

Input Flange Spacer Installation

CHAMFER

Figure 272

Install input flange Spacer.

NOTE: Assemble with chamfer towards bearing cone.

Carrier Cover Installation

Figure 275

With the aid of an alignment pin, install carrier cover.

Figure 273

Apply a continuous .06 [1.5 mm] diameter bead of RTV sealant to carrier cover mounting surface.

Figure 276

Apply Loctite 262 or equivalent to carrier cover screws.

Figure 274

Using appropriate driver install input seal in carrier cover.

NOTE: Position seal with the dust lip facing out.

75

Figure 277

Install (9) carrier cover screws with lock washers.

NOTE: Do not install cover screws at this time in the two hole shown above if using a chain to install differential assembly. Reattach chain as shown in axle disassembly figure 42.

48T300 Drive Axle

Service Manual

Figure 278

Tighten cover screws to 65-70 LBF/FT [88-95 Nm].

Input Flange Installation

Figure 281

Install input flange.

NOTES: The flange splines are an interference fit which require that the flange be heated or driven on shaft.

When heat is not used pack dust shield cavity with grease.

Figure 279

Pack input shaft oil seal with grease and apply heavy coat to outer lip.

Figure 282

Apply bead of RTV sealant as shown centered

over joint between shaft splines and flange splines.

Figure 280

If replacement is required install input flange dust shield using appropriate driver.

76

Figure 283

Install input shaft nut and washer.

48T300 Drive Axle

Service Manual

Figure 284

Tighten input flange nut to

525-560 LBF/FT [712-759 Nm].

Checking Ring Gear Contact Pattern

Figure 286

Compare ring gear convex tooth pattern with right hand gear tooth contact chart on page 24. Follow instructions on chart to correct pattern problems.

Figure 285

Paint (6) to (8) ring gear teeth with gear contact checking compound as shown.

While turning input shaft initiate a load on the differential body and ring gear with a length of 2x4 wedged between the differential body and carrier housing.

Rotate input so the pinion gear teeth make several passes through the checking compound in each direction.

Figure 287

Compare ring gear concave tooth pattern with right hand gear tooth contact chart on page 24. Follow instructions on chart to correct pattern problems.

77

Figure 288

Install input flange nut cotter pin and bend ends as shown.

48T300 Drive Axle

Service Manual

Thrust Screw Installation

Figure 289

Apply teflon thread sealer to thrust screw.

Figure 292

Tighten thrust screw lock nut to 350 LBF/FT [475 Nm].

NOTE: Observe position of thrust screw flats before torquing to be sure screw did not turn with nut.

Figure 290

Install thrust screw and nut.

Tighten screw until it contacts ring gear.

Figure 291

Using a dial indicator as shown back out thrust screw

.010-.015 [.25-.38 mm] from contact with ring gear.

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48T300 Drive Axle

Service Manual

Spindle and Brake Installation

Figure 293

Apply grease to spindle housing seal ring and install.

Figure 296

Install alignment pin in upper spindle screw hole.

NOTE: Threaded end of pin must engage threads in axle housing a minimum of 1.5 times pin diameter or 2.0 [50.8 mm].

Figure 294

Apply grease to spindle pilot seal ring and install.

Figure 297

Install Spindle. NOTE: Spindle pilot needs to be fully engaged in axle housing. A soft mallet may be necessary to drive spindle into position.

Figure 295

Clean taped holes with solvent and compressed air.

IMPORTANT:

Do not clean/chase threads using a tap.

Apply grease to spindle pilot bore in axle housing.

79

Figure 298

Remove top screw from brake and install lifting device.

Refer to tool drawing on page 99.

48T300 Drive Axle

Service Manual

Figure 299

Apply grease to brake seal ring and install.

Figure 302

Install (12) spindle screws and washers.

IMPORTANT:

New screws are highly recommended for each rebuild.

Housing and screw threads must be clean and dry.

DO NOT use Loctite or lubricant.

Figure 300

Carefully install brake assembly.

Figure 303

Tighten (12) spindle screws to approximately 100 LBF/FT [136 Nm].

Figure 301

Install spindle retaining ring.

80

Figure 304

Remove lifting device from brake.

48T300 Drive Axle

Service Manual

Figure 305

Apply Loctite 262 or equivalent to brake cover screw.

Figure 308

Tighten (13) spindle screws to

1850-2000 LBF/FT [2508-2712 Nm] in a circular pattern.

Hub Installation

Figure 306

Install brake cover screw and washer.

Tighten to 175-190 LBF/FT [240-260 Nm].

Figure 309

Install lifting device on hub.

Figure 307

Remove alignment pin. Install (1) spindle screw and washer. Tighten to approximately 100 LBF/FT [136 Nm].

Reference Figures 302 & 303.

81

Figure 310

Screws and flat washers installed during hub reassembly should be in place as indicated above. If not they should be installed to hold internal gear in hub during handling.

48T300 Drive Axle

Service Manual

Face Seal Installation

Figure 311

Clean face seal bore in brake housing with solvent.

NOTE: Refer to face seal installation procedure on page 20 for detailed instructions.

Figure 314

Carefully press face seal into brake housing.

NOTE: Use sudden and even pressure against tool to push the toric ring into the housing.

Figure 312

Clean face seal bore in wheel hub with solvent.

Figure 315

Carefully press 2nd half of face seal into wheel hub.

NOTE: Use sudden and even pressure against tool to push the toric ring into the hub.

Figure 313

Install face seal and toric ring into installation tool.

Reference Caterpillar tool part number 8T7789-2.

82

Figure 316

Install hydraulic source to brake actuating port and pressurize to 1500 PSI [10342 kPa] to release brake.

48T300 Drive Axle

Service Manual

Figure 317

Align brake friction discs so that the missing teeth

(wide space) on all discs line up with each other.

Figure 320

Lubricate inner diameter of hub seal with oil.

Figure 318

Apply oil to face seal contact surface.

Figure 321

Apply Anti-Seize or Never-Seez lubricant to spindle splines. NOTE: Refer to wheel bearing adjusting procedure on page 19 for detailed instructions.

Figure 319

Apply oil to face seal contact surface.

83

Figure 322

Apply Anti-Seize or Never-Seez lubricant to face of spindle nut.

48T300 Drive Axle

Service Manual

Wheel Bearing Preload Adjustment

Refer to wheel bearing adjusting procedure on page 19 for detailed instructions.

Figure 323

Apply Anti-Seize or Never-Seez lubricant to spindle threads.

Figure 326

Tighten spindle nut to 1200 LBF/FT [1627 Nm] while rotating hub. Lifting strap and chain hoist are being used to rotate hub.

Figure 324

Install hub assembly. It will be necessary to rotate wheel hub slightly to engage brake disc teeth. Do not force as damage to disc teeth could occur.

Figure 325

Install spindle nut. After nut is secure on spindle remove lifting device and the screws and flat washers used for handling.

84

Figure 327

Shock internal hub while rotating wheel hub.

After several revolutions retighten spindle nut to

1200 LBF/FT [1627 Nm].

Repeat steps in figures 326 and 327 as many times as necessary until 1200 LBF/FT [1627 Nm] does not advance nut after shocking.

48T300 Drive Axle

Service Manual

Figure 328

Loosen spindle nut 1/4 to 1/2 turn and shock hub until a slight bearing end play is achieved and the hub rotates freely.

Figure 330

Tighten spindle nut to 600 LBF/FT [813 Nm].

Figure 329

Check no-load rolling torque of hub using a torque wrench and adapter bar or other appropriate measuring device Rolling torque should be between 10-50 LBF/FT [14-68 Nm].

If higher open brake bleeder, rotate hub and shock brake to release brake.

If brake doesn’t release apply 3 PSI [21 kPa] to cooling cavity of brake with bleeder open.

Record no-load value.

Figure 331

Install spindle nut lock plate.

85

Figure 332

Tighten spindle nut until 1st of (3) pairs of holes in lock plate line up with tapped holes in internal hub.

48T300 Drive Axle

Service Manual

Figure 333

Check rolling torque of hub. This value should be

50-80 LBF/FT [68-108 Nm] over the no-load reading recorded in step on figure 329.

If reading does not fall within specification refer to wheel bearing adjustment procedure items 7 or 8 on page 19.

Figure 335

Remove air test plumbing and install brake cooling port plugs. Tighten inlet plug to 30-35 LBF/FT [41-47 Nm] and outlet plug to 45-50 LBF/FT [61-68 Nm].

Brake Cavity and Seal Air Test

Figure 336

Release hydraulic pressure to brake actuating port and remove hydraulic plumbing. Install brake actuating port plug and tighten to 20-25 LBF/FT [27-34 Nm].

Figure 334

Perform brake cavity and seal air test using a gauge, shut off valve and regulator as shown or equivalent.

Apply 12 PSI [83 kPa] to brake through the cooling port and close valve. Brake must hold

12 PSI [83 kPa] for 15 seconds with no drop in pressure.

If leaks occur, determine cause, repair and retest.

86

Figure 337

Apply Loctite 262 or equivalent to

(6) spindle nut lock plate screws and install.

48T300 Drive Axle

Service Manual

Figure 338

Tighten spindle nut lock plate screws to

25-28 LBF/FT [34-38 Nm].

Differential and Carrier Installation

Figure 341

Install (4) differential mounting tapered dowels.

Figure 339

Apply .09 [2.3 mm] continuous bead of RTV sealant to

Differential and carrier mounting surface of axle housing.

Figure 342

Install (14) differential mounting stud washers.

Figure 340

Install differential and carrier assembly.

87

Figure 343

Apply Loctite 262 or equivalent to differential mounting stud threads.

48T300 Drive Axle

Service Manual

Figure 344

Install (3) twelve point differential mounting stud nuts in locations shown. Install (11) six point nuts on remaining studs.

Figure 347

Apply Loctite 262 or equivalent to

(2) carrier cover screws and install with lock washers.

Figure 345

Tighten (14) differential mounting nuts to

175-190 LBF/FT [237-258 Nm].

Figure 348

Tighten (2) carrier cover screws to

65-70 LBF/FT [88-95 Nm].

Figure 346

Remove lifting chain, screws and flat washers.

88

Figure 349

Apply teflon thread sealer to differential drain plug and install. Tighten to 40-45 LBF/FT [54-61 Nm].

48T300 Drive Axle

Service Manual

Figure 350

Apply teflon thread sealer to axle drain plug and install.

Tighten to 50-55 LBF/FT [68-74 Nm].

Output Bearing & Retainer Installation

Figure 353

Insert bearing and seal retainer into axle housing while guiding the outer roller bearing into the retainer bore.

NOTE: Shown without oil seal.

Figure 351

Using appropriate driver install inner roller bearing, bearing spacer and outer roller bearing. NOTE: Be sure bearings are properly seated against shaft shoulder.

Figure 354

Install (7) lock washers and apply

Loctite 262 or equivalent to stud threads.

NOTE: Input and drop gear shaft not as shown.

Figure 352

Using appropriate driver install oil seal in bearing and oil seal retainer.

Install bearing and seal retainer o-ring.

NOTES: Dust lip on seal must be positioned with lip facing out. Sealant should not be used.

89

Figure 355

Install (7) nuts and tighten to 40-45 LBF/FT [54-61 Nm].

NOTE: Input and drop gear shaft not as shown.

48T300 Drive Axle

Service Manual

Axle Shaft and Sun Gear Installation

Figure 356

Install axle shaft.

Figure 359

Apply grease and install planetary o-ring.

Figure 357

Install sun gear on axle shaft.

Planetary Installation

Figure 360

Install planetary assembly.

Figure 358

Apply grease to planet sealing ring surface in wheel hub.

90

Figure 361

Apply Loctite 262 or equivalent to (3) mounting screws.

48T300 Drive Axle

Service Manual

Output Flange Installation

Figure 362

Install (3) planetary mounting screws.

IMPORTANT: Align casting eye brows with each other as shown. The (3) screw locations are identified by small cast buttons on the face of the planet carrier.

Figure 365

Pack output shaft oil seal with grease and apply heavy coat to outer lip.

NOTE: Input and drop gear shaft not as shown.

Figure 363

Tighten planetary mounting screws to

380-400 LBF/FT [515-542 Nm].

Figure 366

If replacement is required install output flange dust shield using appropriate driver.

Figure 364

Install planetary oil level and drain plugs and tighten to

30-35 LBF/FT [41-47 Nm].

91

Figure 367

Install output flange.

NOTES: The flange splines are an interference fit which require that the flange be heated or driven on shaft. When heat is not used pack dust shield cavity with grease.

Input and drop gear shaft not as shown.

48T300 Drive Axle

Service Manual

Figure 368

Apply bead of RTV sealant as shown centered

over joint between shaft splines and flange splines.

NOTE: Input and drop gear shaft not as shown.

Figure 371

Install (2) oil level plugs and tighten to

30-35 LBF/FT [41-47 Nm].

Axle Air Pressure Test

Figure 369

Install flange washer and nut. Tighten output flange nut to 525-560 LBF/FT [712-759Nm].

Figure 372

Remove cooling drain plugs from both brakes.

Remove (1) planetary or axle housing plug and install a gauge, shut off valve and regulator or equivalent as shown.

Apply 12 PSI [83 kPa] to pressurize the complete axle assembly and close shut off valve. Axle must hold 12 PSI [83 kPa] for 15 seconds with no drop in pressure. If leaks occur, determine cause, repair and retest.

Remove air test plumbing and reinstall plugs.

Refer to axle pressure test instructions on page 22.

Figure 370

Install output flange nut cotter pin and bend ends as shown.

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48T300 Drive Axle

Service Manual

BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS

WARNING: DO NOT ATTEMPT TO MAKE ANY REPAIRS ON THE BRAKE

UNTIL THIS TEXT IS COMPLETELY READ AND UNDERSTOOD

AND ALL SAFETY PRECAUTIONS COMPLIED TO.

7.

8.

9.

1.

2.

3.

4.

5.

6.

Disassemble wheel end from spindle up to and including the removal of the wheel hub from the brake discs. NOTE: If axle spindle or axle housing is to be replaced, remove brake as an assembly by removing brake to spindle screws and washers.

Remove brake assembly from spindle.

It is imperative that a special disassembly and reassembly spring compression tool be fabricated before disassembling any part of this brake; a drawing of the tool is included on page 98.

Install spring compression tool main section over axle spindle, through brake discs and against the piston pressure ring.

Install the bolt plate and bolts over the spindle. Back the bolts out far enough so they do not contact the cylinder face.

Install spindle nut and tighten securely against compression tool.

Tighten the four (4) compression tool bolts against compression tool cylinder. This will hold the springs in position while removing the brake cover and brake discs.

WARNING: OUTER BRAKE HOUSING COVER IS UNDER 72,000 LBS.

COMPRESSED SPRING PRESSURE AND EXTREME CAUTION

MUST BE TAKEN IN REMOVING THIS COVER. BRAKE COVER

BOLTS MUST BE REMOVED CAUTIOUSLY AND EVENLY. DO NOT

REMOVE BRAKE COVER BOLTS ONE (1) AT A TIME.

With the spring compression tool securely in place, remove the brake cover bolts evenly. Do not remove bolts one at a time.

Remove brake cover and piston from brake housing.

Remove the friction and reaction discs.

Cautiously and evenly turn out a thread at a time, the compression tool bolts. The compression springs will push the piston pressure ring out of the brake housing.

MAKE

WARNING: BEFORE REMOVING COMPRESSION TOOL FROM SPINDLE,

SURE ALL SPRING FORCE IS OFF OF PRESSURE RING AND

RING MOVES FREELY IN BRAKE HOUSING.

10.

Remove spindle nut and remove two piece compression tool.

Refer to pages 37 & 56 for detailed disassembly and reassembly instructions for servicing the internal components of the brake housing and cover.

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BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS - CONT.

1.

2.

3.

4.

6.

7.

8.

5.

Install brake housing on axle.

REASSEMBLY

Install all spring sets.

Position piston pressure ring in brake housing.

Install spring compression tool main section over axle spindle and centered in pressure ring.

Install the bolt plate and bolts over the spindle. Back the bolts out far enough so they do not contact the cylinder face.

Install spindle nut and tighten securely against round compression tool.

Turn the four (4) compression tool bolts in against compression tool cylinder.

Cautiously and evenly in a criss crossing manner, tighten compression tool bolts a thread or two at a time to compress spring sets and push pressure ring into brake housing. Springs are compressed far enough when the tangs on the pressure ring are approximately 1/8 of an inch from being flush with face of brake housing.

9.

Install first steel reaction plate in pressure plate.

10.

Install first friction disc and lining assembly in pressure ring and against first steel plate.

11.

Install second steel reaction ring.

12.

Install second friction disc, aligning the four (4) oil grooves in the second disc with the oil grooves in the first friction disc.

13.

Alternate steel plates and friction discs until five (5) plates and five (5) discs are installed. First plate installed is steel and last disc installed is friction.

NOTE: Always align friction disc oil grooves and careful alignment of friction disc teeth at this time will facilitate wheel hub spline alignment in discs at wheel hub assembly in brake.

14.

Install a new square cut sealing ring in groove in brake housing.

15.

Position brake cover on brake housing, aligning fluid hole marks on cover with holes in housing. Refer to Posi-Stop brake reassembly on page 56.

16 Install cover to housing bolts and washers. If there is a slight gap between cover and housing, carefully and evenly tighten bolts to specified torque.

17.

Carefully and evenly loosen bolts in compression tool. When bolts are away from compression cylinder, remove spindle nut. Remove compression tool and cylinder from spindle and brake.

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48T300 Drive Axle

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BRAKE SPRING COMPRESSION TOOL WELDMENT

95

48T300 Drive Axle

Service Manual

BRAKE SPRING COMPRESSION TOOL BOLT PLATE

Axle Models 53R & 48T

96

48T300 Drive Axle

Service Manual

BRAKE SPRING COMPRESSION TOOL INSTALLATION

97

48T300 Drive Axle

Service Manual

BRAKE PISTON LIFTING TOOL

98

48T300 Drive Axle

Service Manual

WHEEL HUB AND BRAKE LIFTING TOOL

99

48T300 Drive Axle

Service Manual

PINION LOCKING TOOL

100

48T300 Drive Axle

Service Manual

PINION PRESSING TOOL

101

48T300 Drive Axle

Service Manual

HUB SEAL DRIVER

102

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