AxleTech 5000 Series, Maintenance Manual

Page 1: ...Independent Suspension Axle System 5000 Series Maintenance Manual ISAS5 Issued 201 ISAS5 SEPTEMBER 2017 ...

Page 2: ...nts serious per sonal injury or both 3 Follow your company s maintenance and ser vice installation and diagnostics guidelines 4 Use special tools when required to help avoid serious personal injury and damage to com ponents Safety Alerts Torque Symbol and Notes WARNING A Warning alerts you to an instruction or procedure that you must follow exactly to avoid serious personal injury and damage to co...

Page 3: ...isc 2 3 Differential Halfshaft 2 4 Hub Reduction 2 5 Section 3 Inspection Tapered Roller Bearings 3 1 Seals 3 1 Replacing a Wheel Stud 3 1 Fasteners 3 1 Section 4 Assembly Hub Reduction 4 1 Differential Halfshaft 4 6 Brake Disc 4 7 Suspension 4 7 Cardan Joint 4 11 Shock Absorber 4 11 Section 5 Lubrication Oil Change 5 1 Lubrication 5 2 Section 6 Special Tools Tool drawings 6 1 ISAS5 SEPTEMBER 2017...

Page 4: ...4 32 Socket head capscrew M8x1 0x35 grade 10 9 5 1 Drain plug 15 1 Brake assembly 6 2 Lock nut M48x1 5 16 8 Lock washer 7 2 Lock washer 17 8 Socket head bolt M20x1 5x45 grade 10 9 8 2 Ball bearing SKF 6410 18 4 Straddle bearing 9 2 Bearing retainer and seal housing 19 4 Circlip internal 10 2 Seal NCR 23479 20 8 Hex head capscrew 1 3 4 5 3 10 12 13 17 16 14 15 6 7 8 9 11 2 0 1 9 1 8 2 ISAS5 SEPTEMB...

Page 5: ...7 1 Nyloc nut M12x1 75 4 Hex head capscrew M10x1 5x45 26 grade 10 9 28 1 Spacer bushing 9 8 Nyloc nut M10x1 5 29 1 Steering arm 10 1 Shock absorber 30 4 Hex head capscrew M20x2x74 grade 10 9 11 2 Suspension spring Steering ISAS 12 2 Core plug 31 1 Double cardan joint 13 2 King pin 32 8 Lock nut M10x1 5 14 2 Internal circlip 33 8 Stud M10x1 5x70 grade 10 9 15 2 King pin seal Non steering ISAS 16 1 ...

Page 6: ...1 3 Hub Reduction 3 6 3 4 2 30 29 26 28 24 1 27 23 25 5 4 10 11 12 13 14 15 19 20 16 18 21 17 22 ISAS5 SEPTEMBER 2017 ...

Page 7: ...ling kit 20 1 Nut 6 1 ABS ring 21 2 Copper seal 7 1 Seal race 22 2 Socket head capscrew M6x1 0 grade 10 9 8 1 Planetary ring gear hub 23 10 Wheel nut 9 1 Locking washer 24 1 Stub axle assembly 10 1 Spindle nut 25 1 Knuckle 11 1 Spindle ring 26 1 Spindle 12 1 Coupling 27 2 O ring 13 1 Sun gear 28 2 O ring 14 1 Socket head capscrew M14x1 5x90 40 grade 10 9 29 16 Socket head capscrew M16x2 0x40 40 gr...

Page 8: ...al of Springs and Shock Absorber 1 Remove the check strap NOTE Not all vehicles are equipped with check straps If no check strap proceed to step 2 3 Remove the shock absorber upper nut Remove the upper spring cap assembly Remove the shock absorber lower nut 2 Put the wheel end in the maximum hanging position 4 Remove the shock absorber and the 2 springs WARNING Springs must be in the fully extende...

Page 9: ...emove the cardan joint Suspension 2 Remove the fasteners from the cardan joint on the wheel end side 3 Separate the end of the cardan joint using a pry bar WARNING To avoid serious personal injury and damage to components be very careful when using lifting devices for service and maintenance procedures Inspect to make sure that neither lifting strap is damaged Do not subject lifting straps to any ...

Page 10: ...ng bolts from straddle bearing Remove the upper and lower wishbones 1 Remove the 16 brake disc bolts 2 Remove the 4 brake caliper bolts Withdraw the brake caliper and the disc NOTE The AxleTech 5000 ISAS uses Meritor DX225 and DX195 Brakes For maintenance information on the brakes refer to Manual DX 1 E To order this publication call ArvinMeritor s Customer Service Center at 800 535 5560 ISAS5 SEP...

Page 11: ...e Manual MM1 or MM2 Engage the dog clutch while pulling the fork and turning a wheel Hold the fork with a wire to keep the dog clutch engaged 1 Remove the 8 differential shaft bolts 2 Use a pry bar to separate the differential shaft 3 Remove the differential shaft 4 Unlock and remove the shaft nut Remove the lock washer the ball bearing and the seal housing Extract the oil seal from the seal housi...

Page 12: ...ly 2 5 1 Remove the bolts that secure the cover 2 Unlock and remove nut of adjusting screw 5 Remove the end thrust button 7 Unlock the sun gear bolt Maintain the sun gear with jet extractor of bronze ISAS5 SEPTEMBER 2017 ...

Page 13: ...xle shaft 9 Unlock spindle nut 10 Use spanner 5231 to remove the spindle nut 11 Remove spindle nut and lock washer WARNING Gear teeth can be sharp Wear protective gloves to avoid serious personal injury 12 Wearing protective gloves remove the ring gear carrier ISAS5 SEPTEMBER 2017 ...

Page 14: ... drop loading 13 Use a lifting strap to remove the hub assembly If bearing and seal have not been taken out together with the hub remove them from the spindle If necessary remove the spindle end ring WARNING Use a rubber mallet for assembly and disassembly procedures Do not hit steel parts with a steel hammer Pieces of a part can break off and cause serious personal injury 14 Use a rubber mallet a...

Page 15: ...e outside ring Remove outside seal the inner seal and the guide ring 18 Return the hub Remove seal bearing cup and bearing from hub 19 Remove the oil seal and the bearing from the knuckle 20 If necessary remove the spindle of the knuckle ISAS5 SEPTEMBER 2017 ...

Page 16: ... parts by cooling in liquid nitrogen or by heating in hot oil to 80 C 176 F instead of using a press A press is preferred to a shock installer tool The bore must be carefully deburred and cleaned before assembly of the bearing 2 W hen a bearing has been heated for assembly apply a small amount of grease or oil after assembly Seals 1 O rings After removal replace them with new O rings 2 Lip seals C...

Page 17: ...ructions to prevent irritation to the eyes and skin Small amounts of acid vapor are present when applying silicone gasket material To prevent possible serious personal injury make sure there is good ventilation in the work area If the silicone gasket material gets in your eyes flush your eyes with water for 15 minutes Have your eyes checked by a doctor ISAS5 SEPTEMBER 2017 ...

Page 18: ...le 3 Put the other O ring in the groove of the knuckle 4 Apply a bead of silicone sealing compound on the face of the spindle 5 Use Loctite 242 on the screws Tighten them to 190 lb ft 258 Nm 6 Use a driver part number 5294 to insert a lightly greased needle bearing into the spindle 7 Use a seal driver part number 5207 to insert the seal 8 Grease the lower edges of the seal 9 Use Loctite 510 on spi...

Page 19: ...046 to install bearing cup onto the hub 13 Install the bearing onto the hub Pack the bearing with grease Refer to Section 5 14 Use a seal driver part number 5203 to install the oil seal NOTE Lightly lubricate the seal lips WARNING Components will be hot Wear protective gloves to avoid serious personal injury 15 Heat the bearing cone to 175 F 79 C ISAS5 SEPTEMBER 2017 ...

Page 20: ...injury and damage to components take care when using lifting devices during service and maintenance procedures Inspect a lifting strap to ensure that it is not damaged Do not subject lifting straps to shocks or drop loading If the vehicle is equipped with central tire inflation remove the surface protector WARNING Gear teeth can be sharp Wear protective gloves to avoid serious personal injury 18 W...

Page 21: ...he spindle nut torque 22 Back the spindle nut off 1 16 turn NOTE If the lock washer tangs do not align with the adjusting nut back off the adjusting nut enough to align the tangs Do not bend the lock washer tangs back too far If the tangs are bent too far back the lock washer will not function correctly 23 Bend the lock washer tangs into the grooves in the wheel bearing adjusting nut Keep the tang...

Page 22: ...on 28 Install silicone sealing compound in the groove C between the splines A and the face B of cover 29 Install the planet gear carrier cover assembly 30 Use Loctite 242 and install the cover screws Tighten to 44 55 lb ft 60 75 Nm 31 Install the adjusting screw until it contacts the shaft Unscrew by 3 4 turn max to give 0 020 0 060 inch 0 5 mm to 1 5 mm shaft end play ISAS5 SEPTEMBER 2017 ...

Page 23: ...ploded view in Section 1 1 Install the oil seal into the seal housing 2 Install the seal housing the bearing a new lock washer and nut onto the shaft 3 Tighten the nut to 147 184 lb ft 200 250 Nm Then tighten it to next slot and lock it 4 Engage the shaft assembly in the carrier housing The dog clutch must be engaged ISAS5 SEPTEMBER 2017 ...

Page 24: ...on the 16 disc screws and tighten to 22 30 lb ft 30 41 Nm Brake Disc 1 Install the disc and the brake caliper Use Loctite 242 on the 4 caliper screws and tighten to 369 480 lb ft 500 651 Nm Suspension 1 Install the king pin in the tool part number 5293 2 Press the king pin into the upper wishbone ISAS5 SEPTEMBER 2017 ...

Page 25: ...urer s instructions to prevent irritation to the eyes and skin 4 Apply a layer of adhesive Terostat 8590 in the groove on the upper wishbone 6 Carefully slide the seal into position 7 Maintaining the seal in place using a lock wire make one pass around the seal in the groove area using a twisting action tighten the wire until it is holding the seal firmly in place but not cutting rubber seal Posit...

Page 26: ...bone 11 Install the king pin into the knuckle 12 Press into place 10 Apply a bead of silicone sealing compound on the core plug 13 Proceed as with the upper wishbone Refer to steps 3 10 14 Apply Loctite 641 in the bores of the upper wishbone Press in the straddle bearing with a mallet ISAS5 SEPTEMBER 2017 ...

Page 27: ...en to 369 480 lb ft 500 651 Nm 17 Install the upper wishbone Apply Loctite 242 to the screws and tighten to 369 480 lb ft 500 651 Nm 18 With a lifting strap install the wheel end assembly into the lower wishbone Hand tighten the lower king pin nut 19 Install the upper control arm Hand tighten the upper king pin nut 20 Tighten the lower and upper king pin nuts to 572 608 lb ft 775 825 Nm ISAS5 SEPT...

Page 28: ... 60 75 Nm 2 Align the wheel end with the axle Fit fasteners on reducer side and tighten to 44 55 lb ft 60 75 Nm Shock Absorber Top Post Shock 1 Install the springs and shock absorber Install the upper spring cap For ease of assembly maintain with tool part number 5295 Tighten the nuts to 90 ft lbs 150 170 Nm Top Cross Bolt Shock 2 Install the spring shock absorber Install the upper shock mounting ...

Page 29: ...Oil change interval As required by other main tenance actions such as re packing wheel bear ings The oil change interval varies according to the type of vehicle and operating duty Filling Procedure The vehicle must be on a level floor Ensure the lower plug is installed Fill the wheel end until fluid flows from the oil hole Allow enough time for the fluid to flow through the complete assembly Clean...

Page 30: ...Section 6 Special Tools 6 1 Special Tools Drawings Driver handle 5021 Hub seal driver 5203 Cup driver 5046 Washer 5204 ISAS5 SEPTEMBER 2017 ...

Page 31: ...6 2 Seal driver 5207 CTI seal driver 5237 Spanner wrench 5231 CTI seal driver 5238 ISAS5 SEPTEMBER 2017 ...

Page 32: ...Section 6 Special Tools 6 3 3 October 2015 ISAS5 Protector 5239 Bearing driver 5294 King pin muff 5293 Shock absorber clamp 5295 ISAS5 SEPTEMBER 2017 ...

Page 33: ...REVISIONS Updated torque requirements from 155lb ft to 90 110 ft lb on page 4 6 33 per Tammy Marsh 1 T Betena 09 20 2017 ISAS5 SEPTEMBER 2017 ...