AxleTech PSC205, PSC822, PSC824, PSC826, PSS165, PSS166 Service Manual

SERVICE MANUAL

ASM-0910E

October 2019

Planetary Steer Axle

Knuckle Designs

PSS165

PSS166

PSC204

PSC205

PSOC205

PSC353

PSC594

PSC822

PSC824

PSTC824

PSC825

PSC826

PSC1044

PSC1045

PSC1485

PSC1614

PSC1615

PSC1617

PSC1764

PSC1794

PSC1875

PSC1876

PSC4564

PSC4565

PSC5494

i

Table of Contents

Table of Contents

Service Notes ...................................................ii

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

Service Precautions .......................................... v

Towing ............................................................. v

Repair Warnings .............................................. vi

Torque Specifi cations ...................................... vi

Cleaning ......................................................... vi

Damaged Components .................................... vi

Repair Welding ............................................... vii

Omissions ...................................................... vii

General Assembly Instructions ....................... viii

Tapered Roller Bearings ................................ viii

Castings ....................................................... viii

Gears ............................................................ viii

Seals .............................................................. ix

Mounting Surfaces .......................................... ix

Fasteners ......................................................... x

Tapered Ball Joint Removal ............................... x

Introduction .................................................... 1

Description ......................................................1

Axle Designs Covered in This Manual ................2

Axle Designs Not Covered in This Manual ..........2

Identifi cation Tag .............................................2

Model Nomenclature ........................................2

Exploded Views ................................................3

Removal and Disassembly ................................ 5

Steer Knuckle Removal .....................................5

Axle Shaft Assembly Removal ...........................6

King Pin Bushing Inspection .............................8

Axle Shaft Oil Seal and Bushing ........................9

Disassembly .................................................... 9

Steering Universal Joint ....................................9

Wing Bearing Yokes ..........................................9

Round Bearing Yokes or Cardan Joint ............. 10

Constant Velocity Joint .................................. 11

Preparing Parts for Assembly .......................... 11

Cleaning ....................................................... 11

Parts Inspection ............................................ 12

Flush Lubricant From the Axle Housing ........... 12

Assembly and Installation .............................. 12

Assembly of Steering Universal Joint .............. 12

Axle Shaft Bushing & Seal Installation ........... 14

Installation of King Pin Bushings ................... 15

Assembly of Steer Knuckle ............................ 17

Steer Knuckle Adjustment ............................. 18

Adjust Knuckle Vertical End Play .................... 19

Final King Pin Cap Installation ....................... 20

Axle Components .......................................... 21

Axle Shaft & Universal Joint ........................... 21

Spindle, Brake, & Planetary Wheel End ......... 21

Torque Specifi cations .................................... 22

Lubrication Specifi cations.............................. 23

Appendix ....................................................... 24

General Torque Specifi cations ....................... 24

Torque Values for Fasteners ........................... 26

Service Notes

This service manual describes the service and repair procedures for planetary steer axle knuckles. The information contained in this manual is current at the time of publication and is subject to change without notice or liability.

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

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

!

DANGER

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

AxleTech does not authorize anyone, other than highly skilled and experienced individuals, to attempt to utilize the instructions contained in this manual for the 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.

Service Notes

Updates

For the latest version of this manual, please visit the

AxleTech web site at www.axletech.com. AxleTech

Customer Service can be reached at 800-540-2794 or via email at [email protected].

Notations

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

!

DANGER

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

!

WARNING

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

!

CAUTION

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

NOTE

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

ii

Asbestos and Non-Asbestos Fibers Warning


OSHA

*

Toxic and Hazardous Substances 29 CFR 1910.1001

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

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

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

[A] Negative Pressure Enclosure/HEPA Vacuum System

Method

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

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

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

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

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

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

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

[B] Low Pressure/Wet Cleaning Method

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

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

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

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

(5) The brake support plate, brake shoes and brake components used to attach the brake shoes shall be thoroughly washed before removing the old shoes.

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

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

(k) of this section.

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

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


[D] Wet Method

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

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

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

(4) The use of dry brushing during the wet method operations is prohibited.

[59 FR 40964, Aug. 10, 1994; 60 FR 33972, June 29,

1995; 77 FR 17778, March 26, 2012]

For more information, visit www.osha.gov, or call OSHA at

1-800-321-OSHA(6742), TTY 1-877-889-5627.

*References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, are made to provide further guidance to employers and workers 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.

iv

Service Precautions

Service Precautions

!

DANGER

• ALWAYS WEAR PROPER EYE PROTECTION AND

OTHER REQUIRED PERSONAL PROTECTIVE

EQUIPMENT TO PREVENT PERSONAL INJURY WHEN

PERFORMING VEHICLE SERVICE.

• WORK IN A WELL-VENTILATED AREA.

• NEVER USE GASOLINE, OR SOLVENTS CONTAINING

GASOLINE. GASOLINE CAN EXPLODE.

• DO NOT USE HOT SOLUTION TANKS OR WATER

AND ALKALINE SOLUTIONS TO CLEAN GROUND OR

POLISHED PARTS. DOING SO WILL CAUSE DAMAGE

TO THE PARTS.

• USE HOT SOLUTION TANKS OR ALKALINE

SOLUTIONS CORRECTLY. READ THE

MANUFACTURER’S INSTRUCTIONS BEFORE USING

HOT SOLUTION TANKS AND ALKALINE SOLUTIONS.

THEN CAREFULLY FOLLOW THE INSTRUCTIONS.

• SOLVENT CLEANERS CAN BE FLAMMABLE,

POISONOUS, AND CAUSE BURNS. EXAMPLES

OF SOLVENT CLEANERS ARE CARBON

TETRACHLORIDE, EMULSION-TYPE, AND

PETROLEUM-BASED CLEANERS. READ THE

MANUFACTURER’S INSTRUCTIONS BEFORE

USING A SOLVENT CLEANER, THEN CAREFULLY

FOLLOW THE INSTRUCTIONS. ALSO FOLLOW THE

PROCEDURES BELOW.

• PLACE THE VEHICLE ON A LEVEL FLOOR AND

CHOCK THE WHEELS TO HELP PREVENT THE

VEHICLE FROM MOVING. NEVER WORK UNDER A

RAISED VEHICLE SUPPORTED BY ONLY A FLOOR

JACK. ALWAYS SUPPORT A RAISED VEHICLE WITH

SAFETY STANDS. CHOCK THE WHEELS AND MAKE

SURE THE UNIT WILL NOT ROLL BEFORE RELEASING

BRAKES. A JACK CAN SLIP OR FALL OVER. SERIOUS

PERSONAL INJURY CAN RESULT.

v

• IMPROPER JACKING AND SUPPORT METHODS CAN

CAUSE STRUCTURAL DAMAGE THAT RESULTS IN

LOSS OF VEHICLE CONTROL, SEVERE PERSONAL

INJURY OR DEATH. REFER TO THE VEHICLE

MANUFACTURER FOR PROPER JACKING AND

SUPPORT METHODS.

!

WARNING

FOLLOW THE SPECIFIED PROCEDURES IN THE INDICAT-

ED ORDER TO AVOID PERSONAL INJURY OR EQUIPMENT

MALFUNCTION/DAMAGE.

BEFORE STARTING A VEHICLE:

• Sit in the driver’s seat

• Place the shift lever in neutral

• Set the parking brake

BEFORE WORKING ON A VEHICLE OR LEAVING THE CAB

WITH ENGINE RUNNING:



• Chock the wheels

WHEN PARKING THE VEHICLE OR LEAVING THE CAB:



!

CAUTION

• DO NOT RELEASE THE PARKING BRAKE OR

ATTEMPT TO SELECT A GEAR UNTIL THE AIR

PRESSURE IS AT THE CORRECT LEVEL.

• TO AVOID DAMAGE TO THE TRANSMISSION DURING

TOWING:


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

• DO NOT OPERATE VEHICLE IF THE ALTERNATOR

LAMP IS LIT OR IF THE GAUGES INDICATE LOW

VOLTAGE.

Towing

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

Repair Warnings

!

DANGER

USE OF OTHER THAN RECOMMENDED TOOLS, PARTS,

AND INSTRUCTIONS LISTED IN THIS PUBLICATION MAY

PLACE THE SAFETY OF THE SERVICE TECHNICIAN OR

VEHICLE DRIVER IN JEOPARDY.

DO NOT WELD REPAIR, HEAT, BEND, OR RECONDITION

AXLE COMPONENTS. THIS WILL REDUCE COMPONENT

STRENGTH, VOID AXLETECH’S WARRANTY, AND CAN

RESULT IN SERIOUS PERSONAL INJURY AND DAMAGE

TO COMPONENTS. ALWAYS REPLACE DAMAGED OR

OUT-OF-SPECIFICATION COMPONENTS.

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

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

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

• The location of components varies with each OEM.

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

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

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

Torque Specifi cations

• Tightening torque specifi cations indicated in this manual must be adhered to at all times.

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

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

Service Precautions

Cleaning

• Remove gasket material using a gasket scraper taking care not to damage machined surfaces.

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

NOTE: NEVER direct full pressure at any of the seals

(input shaft, wheel hubs, or brakes).

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

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

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

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

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

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

Damaged Components

• All damaged components must be replaced by new components.

• Clean and repair the threads of fasteners and holes.

Use a die or tap of the correct size or a fi ne fi le for this purpose.

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

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

• Always use genuine AxleTech replacement parts.

vi

Service Precautions

Repair Welding

!

DANGER

THE HIGH TEMPERATURE CAUSED BY THE OPEN FLAME

FROM A CUTTING TORCH CAN IGNITE THE OIL IN THE

AXLE HOUSING AND CAN CAUSE SERIOUS PERSONAL

INJURY.

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

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

Please contact AxleTech if you believe that repair welding will work for your particular situation.

Omissions

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

vii

General Assembly Instructions

Tapered Roller Bearings

!

CAUTION

DRY BEARINGS WITH CLEAN PAPER OR RAGS. NEVER

USE COMPRESSED AIR, WHICH CAN CAUSE ABRASIVE

PARTICLES TO CONTAMINATE THE BEARINGS. DAM-

AGE TO COMPONENTS AND REDUCED LINING LIFE CAN

RESULT.

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

Bearings should be replaced when:

• Bearing surfaces show abnormal wear

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

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

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

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

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

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

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

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


During disassembly:

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

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

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

During assembly:

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

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

• Check the cleanliness of the bearing:

• If the bearing is new, unpack it immediately before assembly.

• Used bearings should be cleaned with petrol or benzine and then oiled.

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

• Bearings are installed the easiest by cooling or heating (in hot oil to 80°C) instead of using a press.

Do not apply any shock or impact techniques (like hammering) to install the bearings.

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

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

Castings

• Inspect for damage or cracking. Replace as required.

NEVER weld to repair the casting.

Gears

• Inspect for pitting or damage. Replace as required.

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

• Replace thrust washer, diff erential side gear, and pinion gear with a new matched set. Do not mix old and new parts. Damage to components can result.

viii

ix


Seals

!

WARNING

WHEN APPLYING SOME SILICONE GASKET MATERIALS,

SMALL AMOUNTS OF ACID VAPOR ARE PRESENT. TO

PREVENT POSSIBLE SERIOUS INJURY, THE WORK AREA

MUST BE WELL-VENTILATED. IF THE SILICONE GASKET

MATERIAL GETS INTO YOUR EYES, FLUSH THEM WITH

WATER FOR 15 MINUTES. HAVE YOUR EYES CHECKED

BY A DOCTOR AS SOON AS POSSIBLE.

Recommended Lubricant: Gear Oil

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

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

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

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

0.125" (3.18 MM)

DIAMETER

SILICONE GASKET

MATERIAL BEAD

!

CAUTION

TOO MUCH GASKET MATERIAL CAN BLOCK LUBRI-

CATION PASSAGES. DAMAGE TO COMPONENTS CAN

RESULT.

During assembly:

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

• Lubricate properly:

• Lubricate the entire interior surface of the ring and primarily the seal lips.

• Pack the space between the lips with grease.

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

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

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

Mounting Surfaces

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

Product characteristics:

• Color: Grey

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

• Temperature Resistance:

-67 to 392°F (-55 to 200°C)

• TO BE USED WITH CARE:

Avoid any contact with eyes and skin.

During disassembly:

• In the event of sticking, tap the parts to break the

Loctite fi lm.

• Remove particles of Loctite as thoroughly as possible.

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

• Let all components dry completely.

During assembly:

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

• Assemble the parts and tighten to the required torque.

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

• Total setup time: 18 to 24 hours

Fasteners

When installing fasteners without pre-applied adhesive,

Loctite 243 Blue Threadlocker must be used unless otherwise stated.

NOTE: Do not apply adhesives or sealants to fasteners with pre-applied adhesive, or to fastener holes.

Product characteristics:

• Color: Pale blue

• Temperature Resistance:

-67 to 302°F (- 55 to 150°C)

• TO BE USED WITH CARE:

Avoid any contact with eyes and skin.

During disassembly: to a worn head or unusually high breakaway torque, the locking strength can be reduced by heating the threaded area to approximately 300°F (150°C). Heat slowly to avoid thermal stresses on the diff erential case and gears.

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

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

• Let all components dry completely.

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

• Replace washers if damaged.

• Clean and repair threads of fasteners and holes.

Use a die or tap of the correct size or a fi ne fi le for this purpose.


!

CAUTION

THREADS MUST BE WITHOUT DAMAGE AND CLEAN SO

THAT ACCURATE ADJUSTMENT AND CORRECT TORQUE

VALUES CAN BE APPLIED TO FASTENERS AND PARTS.

During assembly:

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

• Assemble the parts and tighten to the required torque.

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

10 minutes after assembling.

NOTE: To reduce setup time, spray Loctite 7649 Locquic

Primer N activator on the threads, allow to evaporate, and then apply Loctite 243.

Tapered Ball Joint Removal

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

“shock” the tapered joint loose and is a common practice by AxleTech Service.

x

Introduction

Introduction

Description

This maintenance manual is intended to cover the recommended disassembly/assembly procedures of the AxleTech planetary steering axles steer knuckle/king pin designs.

The steer knuckles on a particular axle model will vary dependent on the wheel brake and tie rod design selected by the

OEM specifi cation; but, service of the steer knuckle/king pin assembly is very similar. Axle shaft designs may also vary by specifi c OEM requirements in some axle models. There are two basic king pin designs which are covered by this manual: the sealed and non-sealed king pin designs, as shown in the illustrations below.

When replacing parts, only use factory original parts and parts sets. Parts must be ordered from AxleTech International.

Any damage to parts not described in this manual must be repaired or replaced using original parts.

SEALED

DESIGN

KING PIN

GREASE SEAL

NON-SEALED

DESIGN

AXLE

HOUSING

STEERING

AXLE SHAFT

AXLE HOUSING

BUSHING

AXLE HOUSING

OIL SEAL

THRUST

WASHER

KING PIN

PLUG

LOWER KING

PIN CAP

KING PIN

CAPSCREW

UPPER KING

PIN CAP

KING PIN

WASHER

SHIMS

KNUCKLE

GREASE

FITTING

KING PIN KING PIN

GREASE SEAL

SPINDLE

SPINDLE

OIL SEAL

SPINDLE

BUSHING

GREASE

FITTING

1

ALTERNATE CONSTRUCTION

TYP–TOP AND BOTTOM KING PIN

Introduction

Axle Designs Covered in This Manual

The following knuckle and king pin designs are covered in this manual.

• Non-sealed king pin

• Sealed king pin with grease seal on king pin

• Sealed king pin with grease seal in knuckle bore

• Inclined king pin with grease seal on king pin

For planetary components, wheel hub, brake components, and spindle service procedures, refer to the appropriate planetary axle wheel end service manual. To obtain these publications, refer to the Service Notes section in this manual.

Identifi cation Tag

All products are identifi ed by the model and serial number. This information is stamped on the identifi cation tag when ordering replacement parts or requesting service repairs.

DO NOT REMOVE OR DESTROY THE IDENTIFICATION TAG.

Axle Designs Not Covered in This

Manual

• Split knuckle

• Tapered bearing king pin

Model Nomenclature

MODEL

CUST No.

SERIAL No.

RATIO DATE

P S C 1 7 6 4 HDB 200

Last Digit — Carrier

Designation for

Base Model Number

First Two or Three Digits

Wheel-End Designation

(Basic Model Number)

Exact

Specification

P

N

= Planetary

= Non-Drive

Examples:

R = Rigid

S = Steering

PSS 166 N 103

PSC 826 RSA 203

PSC 5494 HDB 210

Housing Type Designation

C = Integral Cast

S = Fabricated

Brake Type:

Only If Applicable:

T = Transmission on Carrier

O = Oscillating or Pin Mount

L = Mounting Other Than Pad

With Drilling

DLH — 17 in. (432 mm) Hydraulic Drum — (Dual

Leading Hydraulic)

H — Hydraulic Drum

HDB — Hydraulic Dry Disc

M — Mechanical Drum

N — None

NR — With Rotor Less Calipers

P — CamMaster ® “P” Series Cam

RDA — StopMaster ® Wedge (Dual Air Chamber)

RDH — StopMaster ® Wedge (Dual Hydraulic Cylinders)

RSA — StopMaster ® Wedge Single Air Chamber

RSH — StopMaster ® Wedge (Single Hydraulic Cylinders)

2

Introduction

Exploded Views

6

5

7

4

6

5

7

1

3

ALTERNATE STEERING ARM

9

5

2

8

15

12

13

14

16

10

11

3

6

7

4

5

8

2

3

Item Description

1 King Pin Bushing

Upper King Pin Cap

Upper King Pin Cap with Integral Steer Arm

Upper King Pin Cap Capscrew (Long)

Upper King Pin Cap Capscrew (Short)

Upper King Pin Cap Capscrew Washer

Upper King Pin Cap Grease Fitting

Upper King Pin Cap Shims

Item Description

9 Steer Knuckle

10 Steer Knuckle Stop Screw

11 Steer Knuckle Stop Screw Lock Nut

12 Lower King Pin Cap Thrust Washer or Grease Seal

13 Lower King Pin Cap Shims

14 Lower King Pin Cap

15 Steer Axle Shaft - Constant Velocity Style

16 Steer Knuckle Tie Rod Clevis Bushing

Introduction

6

2

3

1

5

4

2

NON-SEALED KING PIN DESIGN SHOWN

13

8

7

10

9

11

12

15

6

7

8

Item Description

3

4

1

2

5

Upper King Pin Cap

Upper King Pin Cap Capscrew (Long)

Upper King Pin Cap Capscrew (Short)

Upper King Pin Cap Grease Fitting


Steer Knuckle

Steer Knuckle Stop Screw

Steer Knuckle Stop Screw Lock Nut

Item Description




12 Lower King Pin Cap Capscrew

13 Steer Axle Shaft - Cardan Style (Typical)

14 Steer Knuckle Tie Rod Assembly with Clevis Ends

15 Steer Knuckle Tie Rod with Ball Stud Ends

4

5

Removal and Disassembly


!

WARNING

TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR EYE

PROTECTION WHEN PERFORMING VEHICLE MAINTE-

NANCE OR SERVICE.

PARK THE VEHICLE ON A LEVEL SURFACE. BLOCK THE

WHEELS TO PREVENT THE VEHICLE FROM MOVING.

SUPPORT THE VEHICLE WITH SAFETY STANDS. NEVER

WORK UNDER A VEHICLE SUPPORTED ONLY BY JACKS.

JACKS CAN SLIP AND FALL OVER. SERIOUS PERSONAL

INJURY AND DAMAGE TO COMPONENTS CAN RESULT.

USE A BRASS OR LEATHER MALLET FOR ASSEMBLY

AND DISASSEMBLY PROCEDURES. NEVER STRIKE

STEEL PARTS WITH A STEEL HAMMER. PIECES OF A

PART CAN BREAK OFF AND CAUSE SERIOUS PERSONAL

INJURY.

Steer Knuckle Removal

1. Remove the hydraulic powering steer cylinder from the knuckle.

2. Remove the tie rod assembly from the knuckle.

For tie rods with ball stud ends:

It may be necessary to use a brass or plastic mallet to strike the knuckle arm to loosen the tapered ball stud.

Drive the ball stud out of the knuckle. DO NOT damage the threads.

3. Remove other components interfering with knuckle removal.

4. Mark the upper right, lower right, upper left, and lower left king pin caps to ensure they will be installed in their original location during axle assembly.

5. Remove the capscrews and washers from the lower king pin cap. Use two 0.5-13 UNC, 2B thread, grade

8 capscrews in the king pin cap puller holes to remove the king pin cap. The king pin cap must be removed squarely to avoid binding in the knuckle bore.

6. Remove the lower king pin cap shim pack and keep it with the king pin cap.

If the shims are damaged and must be replaced:

Measure the original shim pack thickness. Use the same shim pack thickness with new shims for initial assembly.

7. Remove the capscrews and washers from the upper king pin cap. Use two 0.5-13 UNC, 2B thread, grade

8 capscrews in the king pin cap puller holes to remove the king pin cap. The king pin cap must be removed squarely to avoid binding in the knuckle bore.

8. Remove the upper king pin cap shim pack and keep it with the king pin cap.

If the shims are damaged and must be replaced:

Measure the original shim pack thickness. Use the same shim pack thickness with new shims for initial assembly.

9. Remove the king pin cap thrust washer and grease seals.

• For non-sealed king pin bushing:

Usually the thrust washer will come out of the steer knuckle with the lower king pin cap. Remove the thrust washer from the cap. Inspect the washer and cap thrust surfaces for wear or damage.

NON-SEALED KING PIN BUSHING DESIGN

TOP

STEER

KNUCKLE

THRUST

WASHER

LOWER KING PIN CAP

• For sealed king pin bushing with seal piloted on king pin cap:

The grease seals will remain on the king pin caps when removing the caps from the knuckle. Remove and discard the grease seals if they are worn or damaged.

SEALED KING PIN BUSHING DESIGN

TOP

STEER

KNUCKLE


• For sealed king pin bushing with seal piloted in knuckle:

The grease seals will remain in the knuckle bore when removing the king pin caps. Remove the grease seals from the knuckle after removing the knuckle from the axle housing. Discard the grease seals.

!

WARNING

TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE

DAMAGE TO COMPONENTS, BE VERY CAREFUL WHEN

USING LIFTING DEVICES DURING SERVICE AND MAIN-

TENANCE PROCEDURES.

• Inspect to make sure lifting straps are not damaged.

• Never subject lifting straps to any shock or drop loading.

10. Use a lifting device to remove the planetary steer knuckle from the axle housing assembly.

11. Remove the knuckle from the axle housing.

Axle Shaft Assembly Removal

Remove the axle shaft and u-joint assembly from the axle housing.

Use care to avoid damage to the axle housing oil seal.

For planetary gearing, wheel hub, brake components, and spindle removal procedures, refer to the appropriate planetary wheel end service manual.

GREASE

SEAL

LOWER KING PIN CAP

GREASE

SEAL

6


4

6

5

3 3

1

2

12

10

11

13

7

8

9

14

7

6

7

4

5

Item Description

1 Planetary Spider

2 Wheel Hub

3 Upper King Pin Capscrews (4)

Upper King Pin Cap


Steer Knuckle

Steer Knuckle Tie Rod Assembly Nut

Item Description

8 Steer Knuckle Tie Rod Nut Cotter Pin

9 Steer Knuckle Tie Rod Assembly with Ball Stud

Ends

10 Lower King Pin Cap Thrust Washer or Grease

Seal


12 Lower King Pin Cap Capscrews (4)


14 Axle Housing

King Pin Bushing Inspection

Inspect the king pin bushings in the axle housing.

• If the king pin bushings are worn or damaged:

Use one of the following procedures to remove the bushings.

• If the king pin bushings are not worn or damaged:

Proceed to “Axle Shaft Oil Seal and Bushing” on page 9.

Non-Sealed King Pin Bushings

1. Grind off the tack welds holding the expansion plug in the housing bore.

BUSHING


3. Use a sleeve slightly smaller than the housing bore to remove the king pin bushing by driving it TOWARD the outside of the trunnion.

4. Use an emery cloth to clean the housing bores and remove burrs.

Sealed King Pin Bushings

1. Use a sleeve slightly smaller than the housing bore to remove the bushing by driving it TOWARD the outside of the trunnion.

EXPANSION

PLUG

NON-SEALED DESIGN

2. Use a drift that fi ts through the king pin bushing to remove the expansion plug by driving it TOWARD the center of the trunnion.

FLANGED

BUSHING

SEALED DESIGN

2. Use an emery cloth to clean the housing bores and remove burrs.

8

Disassembly

Axle Shaft Oil Seal and Bushing

1. Note the position of the axle shaft oil seal in the housing bore. The oil seal may be installed with the outer face fl ush with the machined counterbore or it may be pressed further into the housing bore. Should the oil seal be installed into machined bore, record oil seal installation depth “X” for later reinstallation of new oil seal assembly.

NOTE:

A new oil seal must be installed in the housing bore at the same depth as the original factory installation.

SEAL FLUSH

WITH COUNTERBORE

FACE

Disassembly

Steering Universal Joint

NOTES:

• NEVER disassemble Permalube universal joints.

Disassembly will void the AxleTech warranty. This style has no grease fi tting on the center parts assembly.

• AxleTech planetary steer axles have three universal joint designs:

• Wing bearing yokes

• Round bearing yokes or cardan joint

COUNTERBORE

FACE

2. Remove the axle shaft oil seal from the housing. DO

NOT damage the housing bore. A damaged bore can allow oil leakage past the outside diameter of a new seal.

SEAL PRESSED

DEEP INTO BORE

• Constant velocity joints

9

AXLE

SHAFT

BUSHING

AXLE

SHAFT

OIL SEAL

3. Inspect the axle shaft bushing. Remove the bushing from the axle housing if it is worn or damaged.

Wing Bearing Yokes

1. Remove the four cross assembly capscrews from each yoke.

2. Inspect the cross assembly.

If the cross assembly requires service:

Replace it with a new assembly. DO NOT disassemble the cross assembly.

Round Bearing Yokes or Cardan Joint

1. Use a suitable tool to remove the snap rings from the two ears in each yoke.

Disassembly

4. Turn the vertical yoke over. Repeat Step 3 to remove the needle bearing and retainer on the opposite side.

2. Place the joint assembly in an open vise with one yoke resting horizontally on top of the vise jaws. DO NOT tighten the vise.

3. Use a suitable soft hammer to tap the upper ear of the vertical yoke several times. Drive the vertical yoke down and push out the upper needle bearing and cap.

The bearing cap has a highly polished surface. DO

NOT mar or scratch the surface during removal.

If the metal retainers have loosened from the bearing caps:

Remove the retainers from the arms of the cross through the hole in the yokes.

5. Remove the yoke by gently moving the yoke off the arms of the cross.

6. Hold the remaining yoke in a vertical position and rest the cross arms on top of the open vise. Repeat Steps

3 and 4.

7. Remove the cross from the yoke by gently separating the cross from the yoke.

8. Clean and inspect all parts. When inspecting the bearings, keep the needles, caps, and retainers together.

9. Replace worn or damaged parts. If replacing a cross, replace the needle bearings. NEVER mix new and used bearings. Replace in sets of four.

10

Preparing Parts for Assembly

Constant Velocity Joint

Remove the rubber boot using the following instructions.

If the balls or raceways are worn or damaged:

Replace the entire shaft and joint assembly.

1. Cut the strapping band from the outside diameter of the rubber boot. Fold the boot back over the long shaft to expose the inner race.

2. Clamp the long shaft into a bronze-jawed vise with the outer or short shaft hanging DOWNWARD.

!

CAUTION

PLACE CUSHIONING MATERIAL UNDER THE HANGING

SHORT SHAFT TO CATCH THE SHAFT WHEN IT IS RE-

LEASED. TAKE SAFETY PRECAUTIONS TO AVOID INJURY

WHEN THE SHORT SHAFT IS RELEASED.

3. Use a bronze drift and hammer to strike the face of the inner race and loosen the outer shaft assembly.

When compressing the locking ring, the short shaft assembly will release.

NOTE: NEVER strike the face of the outer bell housing.

4. Remove the lock ring.

If the lock ring is damaged:

Discard the lock ring. Use a new lock ring for assembly.

5. Remove the rubber boot from the long shaft.

If there is a snap ring at the inner end of the long shaft spline:

Remove the snap ring before removing the boot.

11

Preparing Parts for Assembly

Cleaning

!

WARNING

SOLVENT CLEANERS CAN BE FLAMMABLE, POISON-

OUS, AND CAUSE BURNS. EXAMPLES OF SOLVENT

CLEANERS ARE CARBON TETRACHLORIDE, EMUL-

SION-TYPE CLEANERS AND PETROLEUM-BASED

CLEANERS. TO AVOID SERIOUS PERSONAL INJURY

WHEN USING SOLVENT CLEANERS, CAREFULLY FOL-

LOW THE MANUFACTURER’S PRODUCT INSTRUCTIONS

AND THESE PROCEDURES:

• Wear eye protection.

• Wear clothing to protect skin.

• Work in a well-ventilated area.

• NEVER use gasoline or solvents containing gasoline.

Gasoline can explode.

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

1. Using a gasket scraper and/or an appropriate solvent, remove excess gasket material being careful not to damage ground surfaces.

2. Using a small gasket scraper and/or appropriate solvent, remove excess gasket compound from the thrust button thrust face and bore in the planetary spider. Avoid scratching the thrust face or bore while cleaning. If scratches or gouges deeper than 0.005” are visible, replace the planetary spider.

Parts Inspection

Carefully inspect all disassembled parts before assembly and replace any worn, cracked, or damaged parts. Check for cracks using dye penetrant, magnetic fl ux, or fl uorescent particle testing methods.

Inspect the planetary reduction, planetary gears, sun gear, and ring gear assembly for wear or damage. Replace gears, shafts, or thrust washers that are scored, pitted, ridged, chipped, or worn.

See AMT-0445 - Failure Analysis Service Manual for further information on parts inspection.

Flush Lubricant From the Axle

Housing

1. If the housing bowl has magnets, remove all metallic debris from the magnets.

2. Flush lubricant from the entire axle, including the wheel ends and housing bowl, before assembling the axle.

Assembly and Installation


!

WARNING

TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR EYE

PROTECTION WHEN PERFORMING VEHICLE MAINTE-

NANCE OR SERVICE.

USE A BRASS OR LEATHER MALLET FOR ASSEMBLY

AND DISASSEMBLY PROCEDURES. NEVER STRIKE

STEEL PARTS WITH A STEEL HAMMER. PIECES OF A

PART CAN BREAK OFF AND CAUSE SERIOUS PERSONAL

INJURY.

Assembly of Steering Universal Joint

Round Bearing Yokes or Cardan Joint

NOTE: If replacing the cross, also replace the needle bearing. NEVER mix new and used bearings. Replace in sets of four.

1. Place a needle bearing cap into the ear of the yoke.

2. Use a vise to press the needle bearing cap into the correct position. DO NOT damage the polished surface of the cap.

3. Remove the yoke from the vise. Carefully place one arm of the cross into the yoke and bearing cap.

4. Install the opposite bearing cap into the yoke by hand and align the cross arm.

12


5. Use the vise to press the bearing cap into the yoke and onto the arm of the cross. The cross must move freely in both caps.

If the cross does not move freely:

Remove the cap. Check the alignment of the needle bearings.

6. Use a short plug to push the bearing cups into the yoke past the snap ring grooves. Install the snap rings into the grooves, one in each bearing cap.

7. Repeat Steps 1-6 to install the remaining caps and yokes.

Wing Bearing Yokes

1. If the cross and cap assembly is damaged, replace all the parts with a new assembly.

2. Use the eight capscrews and nuts to attach the cross assembly to the yokes. Tighten the capscrews and jam nuts to the specifi ed torque. See the table below.

Fastener Size

7/16”-20

1/2”-20

Torque lbs. ft. (N · m)

Capscrews Jam Nuts

70-80 (95-108) 20-30 (27-41)

115-135 (155-183) 27-37 (36-50)

3. Lubricate round and wing bearing style caps with grease. Clean, then apply specifi ed grease, until it purges from all four seals.

Grease: NLGI GR2 (Lithium 12-hydroxy stearate with molybdenum disulfi de)

Constant Velocity Joint

NOTE: AxleTech kit number MPS 4707 is available for the

PSC205 axle model. The kit contains a new boot, outer lock ring, stainless strapping, and a lock clip for one shaft assembly.

1. Inspect the constant velocity joint bell housing and race assembly for the correct amount of grease

(approximately 12 ounces). The grease level should be at the back side of the inner race as viewed through the internal spline of the inner race.

NOTE: Grease should be placed around each ball in race and into boot fold cavities, NOT packed near boot/axle shaft journal as some seepage could occur. If necessary, remove contaminants and add

Shell Alvania EP-2 grease or equivalent.

2. Clean the outside of the bell housing and boot groove area.

3. Clean old grease and debris from the spline area and boot sealing area of the inner or long axle shaft.

Inspect the splines, lock ring grooves, and lock rings.

4. Apply a light fi lm of EP-2 grease to the shaft seat diameter for the boot. Use hand pressure to install the new boot on the shaft seating diameter.

INNER LOCK RING

(SOME VERSIONS) BOOT

INNER (LONG)

SHAFT

OUTER LOCK

RING

5. Install the inner, if equipped, and outer lock rings in the grooves of the long shaft.

6. Use a bronze-jawed vise to hold the short shaft, bell housing, and ball races. Position the open end of the bell housing UPWARD.

7. Install the long shaft and boot assembly, with the lock rings in the grooves, into the inner race until the lock ring contacts the chamfer of the inner race.

13

8. Have a second person use a blunt-edged tool, such as a fl at-blade screwdriver, to depress the lock ring into the groove while pushing the long shaft partially into the inner race. Use a plastic mallet, or a mallet and bronze drift, to strike the end of the long shaft and drive the shaft through the inner race. The lock ring must clear the inner race and expand to lock the shaft into position.

9. Verify the long shaft is correctly seated by lightly pulling OUTWARD on the long shaft. The lock ring should resist outward movement. NEVER use excessive force to perform this test.

10. Position the large end of the boot, with the raised circumference seat in the inside diameter of the boot, into the external groove of the bell housing. The boot seat and the groove must be clean and dry. NEVER use sealer or adhesive.

11. Install 1/4” stainless steel strapping with a clip around the boot outside diameter, over the boot groove seating area. Use the strapping and clip from the kit.

12. Use an appropriate tool to tighten the strapping. The boot material must be compressed and puckered under the strap. The strap must be positioned over the bell housing groove.

!

CAUTION

NEVER USE EXCESSIVE HAMMER FORCE TO FLATTEN

THE CLIP EARS OVER THE STRAP END. DAMAGE TO THE

STRAP, BUCKLE, OR BOOT CAN OCCUR FROM EXCES-

SIVE HAMMER FORCE. TAKE CARE NOT TO CREATE

A TEAR IN BOOT MATERIAL WHEN TIGHTENING THE

STRAP/CLIP ASSEMBLY.

13. Verify the boot and strap are positioned correctly. Use a hammer to fl atten the clip ears over the strap end to lock it in. NEVER use excessive hammer force to fl atten the clip ears. Damage to the strap, buckle, or boot can occur.

14. Remove the assembly from the vise. Verify the constant velocity joint is operating correctly and the boot strapping is holding correctly.


Installation of Axle Shaft Bushing & Seal

1. Use an appropriate driver to install a new axle shaft bushing in the axle housing. The bushing must be fl ush with the oil seal counterbore.

SEAL PRESSED

DEEP INTO BORE

AXLE

SHAFT

OIL SEAL

AXLE

SHAFT

BUSHING

!

CAUTION

APPLY A LIGHT FILM OF NON-HARDENING SEALANT ON

THE SEAL BORE. NEVER APPLY EXCESSIVE SEALANT

TO THE SEAL BORE. THE EXCESS MAY BE PUSHED INTO

THE SEAL AND BUSHING. DAMAGE TO THE COMPO-

NENTS CAN RESULT.

2. Inspect the oil seal counterbore in the axle housing.

Use an emery cloth to remove the surface scratches.

Apply a light fi lm of non-hardening sealant on the seal bore. NEVER apply excessive sealant to the seal bore.

The excess may be pushed into the seal and bushing.

14


!

CAUTION

NEVER APPLY EXCESSIVE FORCE WHEN INSTALLING

THE SEAL THAT BOTTOMS ON THE BORE SHOULDER.

EXCESSIVE FORCE CAN DAMAGE THE SEAL AND LEAK-

AGE WILL RESULT.

3. Use an appropriate driver to install a new oil seal. The seal must be square to the bore. The oil seal may be installed with the outer face fl ush with the machined counterbore or it may be pressed further into the housing bore.

SEAL FLUSH

WITH COUNTERBORE

FACE

Installation of King Pin Bushings

Non-Sealed King Pin Bushings

1. Verify the housing bore is clean. Use an emery cloth to remove burrs.

2. Use an appropriate driver to install a new bushing.

Use the old bushing to drive the new bushing to the bottom of the housing bore chamfer.

TACK WELD

FOUR PLACES

COUNTERBORE

FACE

NOTES:

• A new oil seal must be installed in the housing bore at the same depth as the original factory installation.

• NEVER apply excessive force on the seal that bottoms on the bore shoulder. Excessive force can damage the seal and leakage will result. Should the original oil seal have been installed below machined depth, reinstall new oil seal to previously recorded “X” dimension as noted during disassembly.

Bushing must be pressed to bottom of chamfer.

NOTE: Bushing must be pressed to bottom of housing bore chamfer.

If the king pin cap is used for the driver:

Use a bronze drift or plastic mallet on the king pin cap.

3. Insert a king pin cap into the bushing to verify it rotates freely. If binding occurs, the bushing may need to be honed to allow cap installation.

4. Install a new expansion plug with the convex side

TOWARD the axle centerline. Strike the center of the expansion plug to slightly deform and expand the plug until it is tight in the bore. If necessary, grind off excess metal from the original tack welds to allow the new plug to be installed.

5. Tack weld the expansion plug to the housing in four places. The plug must fi t tightly in the housing bore to prevent king pin bushing grease from leaking.

15

Sealed King Pin Bushings

!

WARNING

TAKE CARE USING LOCTITE ADHESIVE TO AVOID SE-

RIOUS PERSONAL INJURY. READ THE MANUFACTUR-

ER’S INSTRUCTIONS BEFORE USING THIS PRODUCT.

FOLLOW THE INSTRUCTIONS CAREFULLY TO PREVENT

IRRITATION TO THE EYES AND SKIN.

1. Verify the housing bore is clean. Use an emery cloth to remove burrs.

2. Use a brush to apply a thin coat of Loctite 680 sealant or equivalent to the housing bore or to the bushing outside diameter near the closed end. NEVER allow any sealant to contact the bushing grooved face where the king pin will contact the bushing. Install the bushing into the housing bore until the fl ange is tightly seated on the housing boss face.

FLANGED

BUSHING


NOTES:

• Kit MPS 4470 has KP bushings, KP caps, grease seals, grease fi ttings, and shims for two wheel ends of the

PSC1485 axle.

• Kit MPS 4465 has KP bushing, KP cap, grease seal, grease fi tting, and shims for one king pin location of the PSC1485 axle.

• Kit MPS 4476 has “oversized” KP bushings, KP caps, grease seals, grease fi ttings, shims, and re-work instructions for the PSC1485 axle where the housing bore for KP bushing is worn (up to 1.452” radius maximum).

SEALED DESIGN

If the bushing is tight in the housing bore:

Insert a king pin cap in the bushing. Use a plastic mallet or bronze drift on the cap to drive the bushing into the housing. Drive the bushing into the bore until the bushing fl ange is tightly seated on the housing boss face.

16


Assembly of Steer Knuckle

!

WARNING

TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE

DAMAGE TO COMPONENTS, BE VERY CAREFUL WHEN

USING LIFTING DEVICES DURING SERVICE AND MAIN-

TENANCE PROCEDURES.

• Inspect to make sure lifting straps are not damaged.

• Never subject lifting straps to any shock or drop loading.

1. Use AxleTech specifi cation number O-617-A or

O-617-B grease to lubricate the king pin bushing bores. For fl anged bushings, also lubricate the thrust faces.

2. Use a lifting device to install the knuckle over the axle housing trunnion end. Align the king pin bore in the knuckle with the axle housing king pin bushing.

NOTE: NEVER install the grease seal on the sealed design cap. The seal is installed after adjusting the knuckle vertical end play.

4

6

5

3 3

7

8

14

2

1

12

5

6

7

2

3

Item Description

1 Planetary Spider

4

Wheel Hub

Upper King Pin Capscrews (4)

Upper King Pin Cap


Steer Knuckle

Steer Knuckle Tie Rod Assembly Nut

17

10

11

13

9

Item Description

8 Steer Knuckle Tie Rod Nut Cotter Pin

9 Steer Knuckle Tie Rod Assembly with Ball Stud Ends



12 Lower King Pin Cap Capscrews (4)


14 Axle Housing

3. Install the upper king pin cap with the original shim pack. If necessary, drive the cap into the knuckle by tightening the mounting screws alternately in small increments to keep the cap straight in the knuckle bore.

4. Install the lower king pin cap using one of the following procedures.

Non-Sealed King Pin Bushing

1. Install the original shim pack on the cap.

2. Apply a liberal coating of AxleTech specifi cation number O-617-A or O-617-B grease into the grooved face of the thrust washer.

3. Install the lower thrust washer on the king pin cap with the grooved face against the cap and the washer tangs facing the axle housing.

4. Install the cap, shims, and thrust washer into the knuckle. If necessary, drive the cap into the knuckle by tightening the mounting screws alternately in small increments to keep the cap straight in the knuckle bore. The thrust washer tangs must engage the slots in the axle housing for correct seating of the cap.

5. Tighten the capscrews. DO NOT apply the fi nal torque until the knuckle end play has been set.

Sealed King Pin Bushing

1. Install the original shim pack on the lower cap.

NOTE: DO NOT install the grease seal onto the king pin cap or into the knuckle bore at this time.

2. Install the cap into the knuckle. Tighten the mounting screws alternately in small increments to keep the cap straight in the knuckle bore.

3. Tighten the capscrews. DO NOT apply fi nal torque until the knuckle end play has been set.


Steer Knuckle Adjustment

Knuckle vertical end play is adjusted with shims between the king pin caps and the steer knuckle. Use one of the following methods to measure the knuckle vertical end play.

Feeler Gauge Method

1. Use a hydraulic jack under the lower king pin cap to force the knuckle to its maximum UPWARD position.

2. Use a feeler gauge to measure the gap.

For fl anged-type sealed king pin bushings:

Measure between the upper king pin cap shoulder and the top surface of the king pin bushing.

For non-sealed king pin bushings:

Measure between the upper king pin cap shoulder and the top machined housing boss surface.

3. Compare the measurement to the specifi cation.

a. If the end play is within 0.003-0.010” (0.076-

0.254 mm) total movement of the knuckle:

For sealed king pins:

Proceed to “Final King Pin Cap Installation” on page 20.

For non-sealed king pins:

Tighten the king pin cap mounting capscrews to the ”Torque Specifi cations” on page 22 .

b. If the end play is not within 0.003-0.010” (0.076-


Record the actual measured end play.

Adjust the end play using the procedure under

“Adjust Knuckle Vertical End Play” on page 19.

18


Dial Indicator Method

1. Attach a dial indicator to a fi nished surface on the knuckle to record the knuckle vertical movement relative to the axle housing.

2. Use a hydraulic jack under the lower king pin cap to raise the knuckle to its maximum UPWARD position.

3. Compare the measurement to the specifi cation.

If the end play is within 0.003-0.010” (0.076-


For sealed king pins:

Proceed to “Final King Pin Cap Installation” on page 20.

For non-sealed king pins:

Tighten the king pin cap mounting capscrews to the ”Torque Specifi cations” on page 22 .

a. If the end play is not within 0.003-0.010” (0.076-


Record the actual measured end play.

Adjust the end play using the following procedure.

Adjust Knuckle Vertical End Play

1. Remove the upper and lower king pin caps. Remove the shim packs and measure the total shim pack thickness, upper plus lower shim pack thickness.

Record the total thickness.

2. Subtract the actual measured end play, Step 3B above, from the total thickness. Divide the result by 2.

3. Adjust the lower shim pack thickness to equal the value determined in Step 2. If the exact thickness cannot be obtained, choose the nearest thicker pack.

4. Adjust the upper shim pack thickness to equal the value determined in Step 2 plus 0.005” (0.127 mm).

Example

Actual end play = 0.020” (0.508 mm)

Total shim pack thickness = 0.066” (1.676 mm)

0.066 – 0.020 = 0.046”

(1.676 – 0.508 = 1.168 mm)

0.046 divided by 2 = 0.023”

(1.168 divided by 2 = 0.584 mm)

New lower shim pack thickness = 0.023” (0.584 mm)

New upper shim pack thickness = 0.023 + 0.005 =

0.028” (0.584 + 0.127 = 0.711 mm)

5. Proceed to “Final King Pin Cap Installation” on page

20.

19

Final King Pin Cap Installation

Sealed King Pin

1. Install the grease seal.

For cap-piloted seals:

Install the seal on the upper and lower king pin cap.

For knuckle-piloted seals:

Install the seal in the knuckle bore.

2. Install the new shim packs on the upper and lower caps.

3. Install the upper cap assembly into the knuckle. Use the mounting capscrews to drive the cap into the knuckle. Tighten the capscrews alternately in small increments to keep the cap straight in the knuckle bore. The cap will push the knuckle-piloted grease seal to its fi nal position in the bore. See “Torque

Specifi cations” on page 22 .

4. Repeat Step 3 to install the lower cap assembly into the knuckle.

5. Grease the upper and lower bushings through the grease fi tting in the king pin cap. Apply grease until it fl ows from the grease seal.


Non-Sealed King Pin

1. Install the new shim pack on the upper king pin cap.

2. Install the upper king pin cap into the knuckle. Use the mounting capscrews to drive the cap into the knuckle.

Tighten the capscrews alternately in small increments to keep the cap straight in the knuckle bore. See

“Torque Specifi cations” on page 22 .

3. Install the new shim pack on the lower king pin cap.

4. Grease the grooved face of the lower thrust washer.

Place the washer on the king pin cap with the grooved face contacting the king pin cap surface.

!

CAUTION

THE THRUST WASHER TANGS MUST ENGAGE THE

SLOTS IN THE AXLE HOUSING. IF THE TANGS ARE NOT

CORRECTLY ENGAGED IN THE SLOTS, COMPONENT

DAMAGE WILL OCCUR.

5. Install the lower cap, shim pack, and thrust washer into the knuckle. The thrust washer tangs must engage the slots in the axle housing. Using the mounting capscrews, drive the cap into the knuckle. Tighten the capscrews alternately in small increments to keep the cap straight in the knuckle bore.

6. Tighten the capscrews to the correct torque specifi cation after confi rming the thrust washer is correctly oriented. See “Torque Specifi cations” on page 22 .

7. Grease the upper and lower king pin bushings through the grease fi tting in the king pin cap. The lower thrust washer grooved face may not receive grease unless the knuckle assembly is pushed UPWARD, such as when the axle is supporting the vehicle with the tire on the ground.

20


Axle Components

1. Connect the tie rod to the knuckle. See “Torque

Specifi cations” on page 22 .

2. Connect the power steering cylinder to the knuckle.

Refer to the vehicle manufacturer’s procedures for torque specifi cations.

3. Install brake-related components as necessary.

Axle Shaft & Universal Joint

The following procedure applies to shafts with either the cardan universal joint or the constant velocity joint.

1. Apply AxleTech specifi cation number O-617-A or

O-617-B grease to the oil seal lip and bushing in the axle housing.

2. Apply grease to the seal journals on the axle shaft assembly.

3. Insert the axle shaft assembly into the housing until it engages the side gear of the diff erential. Use care to avoid damage to the oil seal when installing the axle shaft.

Spindle, Brake, & Planetary Wheel

End

Refer to the appropriate planetary wheel end service manual for spindle, brake, and planetary wheel end installation procedures. To obtain these publications, refer to the

Service Notes section in this manual.

For measuring and adjusting the toe setting procedures, refer to the following publications:

• ESM-0093 - Planetary Rigid & Steer Axle Wheel Ends

Service Manual

• ESM-0095 - Planetary Axle Wheel Ends: Covered

Planetary Spider Design Service Manual

• ESM-0100 - Planetary Axle Wheel Ends: Coverless


For lubrication information, refer to the following publications:

• LMT-0001 - Preventative Maintenance & Lubrication

Service Manual

• ESM-0093 Planetary Rigid & Steer Axle Wheel Ends

Service Manual

• ESM-0095 - Planetary Axle Wheel Ends: Covered


• ESM-0100 - Planetary Axle Wheel Ends: Coverless


21



1

3

2

A

3

2

A

1 4 5

1

8

3

1

1

Item

1

2

Fastener Location

King Pin Cap Capscrew

PSOC205 Only:

Apply Adhesive STF 02-462

Tie Rod Ball Stud Nut

3 Steer Stop Bolt Jam Nut

4 Tie Rod Ball Stud Jam Nut

5 Ball Joint End Tie Rod Clamp Bolt

6 Tie Rod Yoke Clamp Bolt Nut

7 Tie Rod Yoke Bolt

8 Yoke Lock Plate Capscrew

Size

9/16"-12

3/4"-10

7/8"-14

1"-12

M14x2.0

5/8"-18

7/8"-14

1-1/4"-12

1-1/2"-12

1/2"-13

7/8"-14

1"-14

1-1/4"-12

1-1/2"-12

1"-16

1-1/4"-12

5/8”-18

1/2”-20

5/8”-18

(PSC5494 only)

3/4"-16

7/8"-14

7/8"-14

7/16"-14

6

7

D

1 lbs. ft.

130-165

310-400

575-750

850-1100

150-170

60-115

200-250

400-550

475-550

50-65

150-190

250-300

275-350

300-400

165-200

165-200

80-90

35-45

90-100

Torque

N · m

176-224

420-542

780-1017

1152-1491

203.4-230.5

81-156

271-339

542-746

644-746

68-88

203-258

339-407

373-475

407-542

224-271

224-271

108-122

47-61

122-136

360-470

575-750

0-5

60-75

488-637

780-1017

0-7

81-102

22

Lubrication Specifi cations

Lubrication Specifi cations

Typical Axle Housing Oil Capacities for Planetary Steer Axle Models*

Axle Model

PSS165

PSS166

PSC204

PSC205

PSOC205

PSC353

PSC594

PSC822

PSC824

PSTC824

PSC825

PSC826

PSC1044

PSC1045

PSC1485

PSC1614

PSC1615

PSC1617

PSC1764

PSC1794 (R155)

PSC1794 (RS160)

PSC1875

PSC1876

PSC4564

PSC4565

PSC5494

Axle Housing Lube Capacity

(estimated)

Pints Liters

20

20

29

29

29

25

28

??

30

30

30

37

40

40

44

40

40

40

40

52

??

56

54

58

58

64

9.5

9.5

13.7

13.7

13.7

11.8

13.2

??

14.2

14.2

14.2

17.5

18.9

18.9

20.8

18.9

18.9

18.9

18.9

24.6

??

26.4

25.5

27.4

27.4

30.2

* Typical lube quantities are indicated as estimates due to the multiple axle housing length options available.

Actual volumes required for the specifi c axle being serviced should be verifi ed by using the recommended oil fi ll procedure.

23

Appendix


Appendix

24

Appendix

25

Appendix

Torque Values for Fasteners

1. The torque values in the previous tables are for fasteners with a light application of oil on the threads.

2. If the fasteners are dry, increase the torque values by ten percent (10%).

3. If the fasteners have a heavy application of oil on the threads, decrease the torque values by ten percent

(10%).

4. If the size of the fastener being installed is unknown, measure the fastener using the procedures in the following section.

5. Compare the size of fastener measured in Step 4 to the list of fasteners in tables to fi nd the correct torque value.

Measuring American Standard Fasteners

Measuring Metric Fasteners

Y Dimension

(Distance of

10 Threads)

Number of Threads in 1”

X Dimension

(For example

M8 or 8mm) a. Measure the diameter of the threads in millimeters (mm), dimension X.

b. Measure the distance of ten (10) threads, point to point in millimeters (mm), dimension Y.

Make a note of dimension Y.

c. Divide dimension Y by ten (10). The result will be the distance between two threads or pitch.

Example:

Metric size fastener is M8 x 1.25.

• M8 is the diameter of the fastener in millimeters (mm) or dimension X

• 1.25 is the distance between two threads or pitch

X Dimension

(For example 1/2”) a. Measure the diameter of the threads in inches, dimension X.

b. Count the amount of threads there are in 1”.

Example:

American Standard size fastener is 0.50-13.00.

• 0.50 is the diameter of the fastener in inches or dimension X

• 13.00 is the amount of threads in 1”

26

Customer Service

877-547-3907

+33 (0) 4 77 92 88 92

Customer Service Fax

877-547-3987

Email

OE: [email protected]

Aftermarket: [email protected]

© 2018 AxleTech International LLC. All rights reserved. AxleTech and AxleTech International are registered trademarks of AxleTech International LLC.

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

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ASM-0910E 10/19

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