planetary axle wheel ends - axletech axle wheel ends extrémité de roue à réduction planétaire...

Planetary Axle Wheel EndsExtrémité de roue à réduction planétaireMaintenance Manual 9N Issued 03-07Manuel de maintenance 9N Edité Marche 07

Models/MódelesPRC 785P/485QPRC 785P/485Q W3H

Service Notes

Before You BeginThis maintenance manual describes the correct service and repair procedures for all AxleTech planetary axle models listed on front cover. The information contained in this manual was current attime of printing and is subject to change withoutnotice or liability.

You must follow your company procedures when youservice or repair equipment or components. You mustunderstand all procedures and instructions beforeyou begin to work on a unit. Some procedures requirethe use of special tools for safe and correct service.Failure to use special tools when required can causeserious personal injury to service personnel, as wellas damage equipment and components.

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

Safety Alerts, Torque Symbol and Notes

WARNING A Warning alerts you to aninstruction or procedure thatyou must follow exactly toavoid serious personalinjury.

CAUTION A Caution alerts you to an instruction or procedurethat you must follow exactly to avoid damage to components.

The torque symbol alertsyou to tighten fasteners to a specified torque value.

NOTE: A Note provides informationor suggestions that help you correctly service a component.

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The instructions contained in this Field MaintenanceManual are intended for use by skilled and experienced mechanics knowledgeable in the installation, repair and replacement of the AxleTechproduct described herein. Installation, maintenanceand replacement of such products require a highdegree of skill and experience. The consequences of improper installation, maintenance or replacement(including the use of inferior or substandard components) are grave and can result in product failure and resulting loss of control of the vehicle,possible injury to or death of persons and/or possible

future or additional axle damage. AxleTech does notauthorize anyone other than highly skilled and experienced individuals to attempt to utilize theinstructions contained in this Manual for the installation, maintenance or replacement of the product described herein, and AxleTech shall haveno liability of any kind for damages arising out of (or in connection with) any other use of the information contained in this Manual.

Additional PublicationsFor AxleTech service manuals, please contact:1-877-877-9717 and 248-816-5401 or visit our website at www.axletech.com.

How To OrderOrder items from AxleTech International.

Phone orders are also accepted by calling AxleTechInternational’s Customer Service Center at 877-547-3907 or send a fax to 866-547-3987.

Table of Contents

Asbestos and Non-Asbestos Fibers Warnings ..........................................................................1

Section 1: Exploded ViewsPRC 485Q (with Q Plus™ Cam Brakes) .........................................................................................................2PRC 485 W3H.................................................................................................................................................3PRC 785P .......................................................................................................................................................4PRC 785 W3H.................................................................................................................................................5

Section 2: IntroductionDescription ......................................................................................................................................................6Identification ....................................................................................................................................................7

Section 3: Disassembly

PRC 485Q (with Q Plus™ Cam Brakes) Wheel End Cross SectionPRC 485 Q Plus™ Cam Brake Planetary Axle Wheel End.......................................................................8Brake Drum................................................................................................................................................8Planetary Spider Assembly .....................................................................................................................10Cam Brakes.............................................................................................................................................11Spindle and Brake Spider ........................................................................................................................11

PRC 485 W3H Wheel End Cross SectionPRC 485 W3H Wet Disc Brake Wheel End.............................................................................................13Preliminary Disassembly .........................................................................................................................13Planetary Spider Assembly .....................................................................................................................14Wheel End ...............................................................................................................................................15Spindle and Piston Housing ....................................................................................................................15Wet Disc Brakes ......................................................................................................................................16

PRC 785P Wheel End Cross SectionPRC 785P Planetary Axle Wheel End.....................................................................................................17Brake Drum..............................................................................................................................................17Planetary Spider Assembly .....................................................................................................................19Cam Brakes.............................................................................................................................................20Spindle and Brake Spider ........................................................................................................................20

PRC 785 W3H Wheel End Cross SectionPRC 785 W3H Wet Disc Brake Wheel End.............................................................................................21Preliminary Disassembly .........................................................................................................................21Planetary Spider Assembly .....................................................................................................................22Wheel End ...............................................................................................................................................23Spindle and Piston Housing ....................................................................................................................23Wet Disc Brakes ......................................................................................................................................24

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Table of Contents

Section 4: Prepare Parts for AssemblyClean Ground or Polished Parts....................................................................................................................25Clean Parts with a Rough Finish ...................................................................................................................25Clean Axle Assemblies..................................................................................................................................25Dry Cleaned Parts .........................................................................................................................................25Prevent Corrosion .........................................................................................................................................25Inspect Parts .................................................................................................................................................26Inspect Tapered Roller Bearings...................................................................................................................26Inspect the Bevel Pinion and Ring Gear Sets ...............................................................................................27Inspect the Main Differential Assembly .........................................................................................................28Inspect the Axle Shafts..................................................................................................................................28Inspect the Yoke............................................................................................................................................28Inspect the Brakes ........................................................................................................................................28Repair or Replace Parts ................................................................................................................................28Repair Welding..............................................................................................................................................28Apply Silicone Gasket Material......................................................................................................................29

Section 5: Assembly

PRC 485Q (with Q Plus™ Cam Brakes) Planetary AxlePRC 485Q (with Q Plus™ Cam Brakes) Planetary Axle Wheel End ......................................................30Prepare Parts for Assembly ....................................................................................................................30Spindle, Brake Spider and Brake ............................................................................................................30Wheel End ..............................................................................................................................................31Adjust the Wheel Bearing Preload ..........................................................................................................32Planetary Spider and Gearing Assembly ................................................................................................32Final Assembly ........................................................................................................................................33

PRC 485 W3H Wet Disc BrakePRC 485 W3H Wet Disc Brake Wheel End ............................................................................................34Prepare Parts for Assembly ....................................................................................................................34Spindle and Piston Housing to the Axle Housing....................................................................................34Wet Disc Brakes......................................................................................................................................34Wheel End ..............................................................................................................................................35Toric Ring Face Seal into Wheel Hub and Disc Brake Housing..............................................................37Check for Correct Installation of the TRS Toric Ring Seal ......................................................................39Wheel Hub to Spindle Assembly ............................................................................................................40Adjust the Wheel Bearing Preload ..........................................................................................................41Planetary Spider and Gearing Assembly ................................................................................................41Final Assembly ........................................................................................................................................42Fill Wet Disc Brakes with Hydraulic Fluid ................................................................................................42

PRC 785P Planetary AxlePRC 785P Planetary Axle Wheel End ....................................................................................................43Prepare Parts for Assembly ....................................................................................................................43Spindle, Brake Spider and Brake ............................................................................................................43Wheel End ..............................................................................................................................................44Adjust the Wheel Bearing Preload ..........................................................................................................45Planetary Spider and Gearing Assembly ................................................................................................45Final Assembly ........................................................................................................................................46

Table of Contents

PRC 785 W3H Wet Disc BrakePRC 785 W3H Wet Disc Brake Wheel End ............................................................................................47Prepare Parts for Assembly ....................................................................................................................47Spindle and Piston Housing to the Axle Housing....................................................................................47Wet Disc Brakes......................................................................................................................................47Wheel End ..............................................................................................................................................47Toric Ring Face Seal into Wheel Hub and Disc Brake Housing..............................................................49Check for Correct Installation of the TRS Toric Ring Seal ......................................................................51Wheel Hub to Spindle Assembly ............................................................................................................52Adjust the Wheel Bearing Preload ..........................................................................................................52Planetary Spider and Gearing Assembly ................................................................................................53Final Assembly ........................................................................................................................................54Fill Wet Disc Brakes with Hydraulic Fluid ................................................................................................54

Section 6: SpecificationsPRC 485 Q Plus™ Wheel End Torque Chart................................................................................................55PRC 485 W3H Wheel End Torque Chart ......................................................................................................56PRC 785P Wheel End Torque Chart ............................................................................................................57PRC 785 W3H Wheel End Torque Chart ......................................................................................................58Lubrication Specifications..............................................................................................................................59Lubrication Schedule ....................................................................................................................................59Wet Disc Brake Coolant Specifications ........................................................................................................60Sump and Forced Cooling Systems With Hub Seals ....................................................................................60Coolant Change Intervals..............................................................................................................................60Hydraulic Fluid Specifications ......................................................................................................................60

Section 7: Special ToolsSpindle Nut Tool............................................................................................................................................61Planetary Spider Assembly Tool ..................................................................................................................61Toric Ring Face Seal Assembly Tool ............................................................................................................61

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NON-ASBESTOS FIBERS WARNINGThe following procedures for servicing brakes are recommended to reduceexposure to non-asbestos fiber dust, a potential cancer and lung diseasehazard. Material Safety Data Sheets are available from AxleTech.

Hazard SummaryMost recently manufactured brake linings do not contain asbestos fibers. These brakelinings may contain one or more of a variety of ingredients, including glass fibers, mineralwool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.Scientists disagree on the extent of the risks from exposure to these substances.Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.Silicosis gradually reduces lung capacity and efficiency and can result in seriousbreathing difficulty. Some scientists believe other types of non-asbestos fibers, wheninhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiberdust are known to the State of California to cause lung cancer. U.S. and internationalagencies have also determined that dust from mineral wool, ceramic fibers and silica arepotential causes of cancer.Accordingly, workers must use caution to avoid creating and breathing dust whenservicing brakes. Specific recommended work practices for reducing exposure to non-asbestos dust follow. Consult your employer for more details.

Recommended Work Practices1. Separate Work Areas. Whenever feasible, service brakes in a separate area awayfrom other operations to reduce risks to unprotected persons.2. Respiratory Protection. OSHA has set a maximum allowable level of exposure forsilica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings recommend that exposures to other ingredients found in non-asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.Scientists disagree, however, to what extent adherence to these maximum allowableexposure levels will eliminate the risk of disease that can result from inhaling non-asbestos dust. Therefore, wear respiratory protection at all times during brake servicing, beginning withthe removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)filter approved by NIOSH or MSHA, if the exposures levels may exceed OSHA ormanufacturer’s recommended maximum levels. Even when exposures are expected tobe within the maximum allowable levels, wearing such a respirator at all times duringbrake servicing will help minimize exposure.3. Procedures for Servicing Brakes.a. Enclose the brake assembly within a negative pressure enclosure. The enclosure

should be equipped with a HEPA vacuum and worker arm sleeves. With theenclosure in place, use the HEPA vacuum to loosen and vacuum residue from thebrake parts.

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

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

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

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with aHEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenicsolvents, flammable solvents, or solvents that can damage brake components aswetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filteror by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.When you empty vacuum cleaners and handle used rags, wear a respirator equippedwith a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When youreplace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filterwith care.5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink orsmoke. Shower after work. Do not wear work clothes home. Use a vacuum equippedwith a HEPA filter to vacuum work clothes after they are worn. Launder them separately.Do not shake or use compressed air to remove dust from work clothes. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters withcare, such as in sealed plastic bags. Consult applicable EPA, state and local regulationson waste disposal.

Regulatory GuidanceReferences to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in theUnited States, are made to provide further guidance to employers and workers employedwithin the United States. Employers and workers employed outside of the United Statesshould consult the regulations that apply to them for further guidance.

!ASBESTOS FIBER WARNINGThe following procedures for servicing brakes are recommended to reduceexposure to asbestos fiber dust, a cancer and lung disease hazard. MaterialSafety Data Sheets are available from AxleTech.

Hazard SummaryBecause some brake linings contain asbestos, workers who service brakes mustunderstand the potential hazards of asbestos and precautions for reducing risks. Exposureto airborne asbestos dust can cause serious and possibly fatal diseases, includingasbestosis (a chronic lung disease) and cancer, principally lung cancer and mesothelioma(a cancer of the lining of the chest or abdominal cavities). Some studies show that the riskof lung cancer among persons who smoke and who are exposed to asbestos is muchgreater than the risk for non-smokers. Symptoms of these diseases may not becomeapparent for 15, 20 or more years after the first exposure to asbestos.Accordingly, workers must use caution to avoid creating and breathing dust whenservicing brakes. Specific recommended work practices for reducing exposure toasbestos dust follow. Consult your employer for more details.

Recommended Work Practices1. Separate Work Areas. Whenever feasible, service brakes in a separate area awayfrom other operations to reduce risks to unprotected persons. OSHA has set a maximumallowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted averageand 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to whatextent adherence to the maximum allowable exposure levels will eliminate the risk ofdisease that can result from inhaling asbestos dust. OSHA requires that the following signbe posted at the entrance to areas where exposures exceed either of the maximumallowable levels:

DANGER: ASBESTOS CANCER AND LUNG DISEASE HAZARD

AUTHORIZED PERSONNEL ONLY RESPIRATORS AND PROTECTIVE CLOTHING

ARE REQUIRED IN THIS AREA

2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filterapproved by NIOSH or MSHA for use with asbestos at all times when servicing brakes,beginning with the removal of the wheels.3. Procedures for Servicing Brakes.a. Enclose the brake assembly within a negative pressure enclosure. The enclosure

should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosurein place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.

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

c. If an enclosed vacuum system or brake washing equipment is not available, employersmay adopt their own written procedures for servicing brakes, provided that theexposure levels associated with the employer’s procedures do not exceed the levelsassociated with the enclosed vacuum system or brake washing equipment. ConsultOSHA regulations for more details.

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

e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with aHEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenicsolvents, flammable solvents, or solvents that can damage brake components aswetting agents.

4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter orby wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When youempty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPAfilter approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter,wet the filter with a fine mist of water and dispose of the used filter with care.5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink orsmoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped witha HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do notshake or use compressed air to remove dust from work clothes.6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters withcare, such as in sealed plastic bags. Consult applicable EPA, state and local regulations onwaste disposal.

Regulatory GuidanceReferences to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the UnitedStates, are made to provide further guidance to employers and workers employed withinthe United States. Employers and workers employed outside of the United States shouldconsult the regulations that apply to them for further guidance.

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Asbestos and Non-Asbestos Fibers

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Section 1Exploded View

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION

1 Spindle2 Flat Washer3 Cap Screw4 Wear Sleeve5 Oil Seal Assembly6 Inner Bearing Cone7 Inner Bearing Cup8 O-Ring9 Hub

10 Outer Bearing Cup11 Outer Bearing Cone

12 Machine Screw13 Wheel Stud14 Ring Gear Hub15 Spindle Nut16 Set Screw17 Sun Gear Thrust Washer18 Planetary Sun Gear19 Snap Ring20 Lock Ring21 Ring Gear22 Pinion Shaft

23 Needle Rollers24 Spacer25 Planetary Pinion Gear26 Thrust Washer27 Thrust Button28 O-Ring29 Planetary Spider30 Magnetic Drain Plug31 Spiral Retaining Ring32 Brake Drum

PRC 485Q (with Q Plus™ Cam Brakes)

1

4

2

3

56

7

8

9

10

11

12

13

14

15

18

17

31

32

29

2825

2221

20

23

2324

19

27

26

30

16

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PRC 485 W3H


1 Spindle2 Flat Washer3 Cap Screw 4 Wear Sleeve5 TRS Face Seal Assembly6 Oil Seal Assembly7 Inner Bearing Cone8 Inner Bearing Cup9 O-Ring

10 Hub11 Outer Bearing Cup

12 Outer Bearing Cone13 Machine Screw14 Wheel Stud15 Ring Gear Hub16 Spindle Nut17 Set Screw18 Sun Gear Thrust Washer19 Planetary Sun Gear20 Snap Ring21 Lock Ring22 Ring Gear

23 Pinion Shaft24 Needle Rollers25 Spacer26 Planetary Pinion Gear27 Thrust Washer28 Thrust Button29 O-Ring30 Planetary Spider31 Magnetic Drain Plug32 Spiral Retaining Ring

1

17

4

3

2

5

6

78

9

10

11 12

13

14

15

16

18

19

21

2223

24

25

31

32

28

2627

29

30

24

20

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PRC 785P

45

6

8

7

9

10

11

13

14

15

1618

32

3130

29

2826

22

21

20

23

2425

2723

19


1 Spindle2 Flat Washer3 Cap Screw4 Wear Sleeve5 Oil Seal Assembly6 Inner Bearing Cone7 Inner Bearing Cup8 O-Ring9 Hub

10 Outer Bearing Cup11 Outer Bearing Cone

12 Machine Screw13 Wheel Stud14 Ring Gear Hub15 Spindle Nut16 Sun Gear Thrust Washer17 Set Screw18 Planetary Sun Gear19 Snap Ring20 Lock Ring21 Ring Gear22 Pinion Shaft

23 Needle Rollers24 Spacer25 Planetary Pinion Gear26 Thrust Washer27 Thrust Button28 O-Ring29 Planetary Spider30 Magnetic Drain Plug31 Spiral Retaining Ring32 Brake Drum

2

3

1

12

17

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PRC 785 W3H

2

3

1

4 5

6

78

9

10

1112

13

14

16

17

15

32

2825

20

30

2927

23

24

26

2221

19

18

31


1 Spindle2 Flat Washer3 Cap Screw4 Wear Sleeve5 TRS Face Seal Assembly6 Oil Seal Assembly7 Inner Bearing Cone8 Inner Bearing Cup9 O-Ring

10 Hub11 Outer Bearing Cup

12 Outer Bearing Cone13 Machine Screw14 Wheel Stud15 Ring Gear Hub16 Spindle Nut17 Set Screw18 Sun Gear Thrust Washer19 Planetary Sun Gear20 Snap Ring21 Lock Ring22 Ring Gear

23 Pinion Shaft24 Needle Rollers25 Spacer26 Planetary Pinion Gear27 Thrust Washer28 Thrust Button29 O-Ring30 Planetary Spider31 Magnetic Drain Plug32 Spiral Retaining Ring

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Section 2Introduction

Description[Figure 2.1] AxleTech’s PRC 485Q (with Q Plus™cam brakes) and PRC 785P planetary axlesincorporate a single reduction carrier/differentialassembly with hypoid gearing. They are equippedwith the RS-145 carrier series. The final reduction isof planetary spur designed gearing built into thewheel hubs. The axles have only cast housings.

AxleTech planetary axles permit the hypoid gearingof the carrier and the axle shafts to carry only anominal torsional load. At the same time, theyprovide the highest practical numerical gear reductionat the wheels.

• The hypoid pinion and differential assembly of thefirst reduction is supported by tappered rollerbearings.

• A hardened precision spacer between the innerand outer pinion bearings adjusts and maintainsthe pinion bearing preload.

• The positioning of the threaded adjusting rings inthe carrier leg and cap bores adjusts andmaintains the differential tapered bearing preloadand sets ring & pinion backlash.

Figure 2.1

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

• The planetary gears rotate on planetary shafts thatare mounted on a spider. The planetary gear teethin turn mesh with the teeth of the floating ringgear.

• The hypoid gear set in the carrier transmits powerto the axle shafts and the sun gear of the finalreduction, through the revolving planetary gears,and into the planetary spider.

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

PRC 485Q (with Q PLUS™ CAM BRAKES)

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Section 2Introduction

Identification[Figure 2.2] The exact axle model specification isshown on the identification tag located on the axlehousing.

SINGLE PLANETARY AXLESFigure 2.2

P R __ C 7 8 5 P 100

EXACTSPECIFICATION

R – RIGIDP – PLANETARY

LAST DIGIT:CARRIERDESIGNATIONFOR BASE MODELNUMBER

FIRST TWO ORTHREE DIGITS:WHEEL ENDDESIGNATION (BASIC MODELNUMBER)

HOUSING TYPEDESIGNATION:C – INTEGRAL CAST

ONLY IF APPLICABLE:L – MOUNTING OTHER THAN PAD

WITH DRILLING

BRAKE TYPE:N — NONEP — CAM-MASTER® “P” SERIES CAMQ — CAM-MASTER® “Q” SERIES W3H — DURA-DISC® 14.2 in. (360 mm) WET DISC

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WARNINGTo prevent serious eye injury, always wear safeeye protection when you perform vehiclemaintenance or service.

PRC 485Q (with Q Plus™ CamBrakes) Planetary Axle Wheel End

WARNINGBlock the wheels to prevent the vehicle frommoving. Support the vehicle with safety stands.Do not work under a vehicle that is supportedonly by jacks. Jacks can slip or fall over. Seriouspersonal injury can result.

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! Brake Drum

1. Make sure the vehicle is on a level surface.

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

3. Raise the vehicle so that the wheels of the axle tobe serviced are off the ground. Support thevehicle with safety stands. Refer to the vehiclemaintenance manual for instructions on raisingthe vehicle.

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

5. Rotate the wheel ends so the magnetic drain plugin the planetary spider is at the bottom. Removethe plug. Drain and discard the lubricant from bothwheel ends.

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

OIL SEAL

INNERBEARING

WHEELSTUD

OUTERBEARING

PLANETGEAR

SPIRALRETAININGRING

THRUSTBUTTON

SUNGEAR

SUN GEARTHRUSTWASHER RING

GEAR

O-RING

PLANETARYSPIDERBRAKE

DRUM

O-RINGSPINDLE

AXLESHAFT

PLANETARYPINIONSHAFT

RINGGEARHUB

SETSCREW

SPACER

SPINDLENUT

NEEDLEROLLERS

MAGNETICDRAINPLUG

LOCK RINGWHEELHUB

MACHINESCREW

WEARSLEEVE

Section 3Disassembly

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

WARNINGWhen you work on a spring chamber, carefullyfollow the service instructions of the chambermanufacturer. Sudden release of a compressedspring can cause serious personal injury.

7. If the brake air chamber assembly has a springchamber unit, carefully cage and lock the spring toprevent the spring from activating duringdisassembly.

NOTE: If Meritor automatic slack adjusters are used,refer to Maintenance Manual 4, Automatic SlackAdjuster for the correct adjustment procedure. Toorder this publication, call ArvinMeritor’s CustomerService Center at 800-535-5560.

8. Adjust the brake slack adjuster to retract the brakeshoes to produce clearance between the lining andthe brake drum.

WARNINGTo prevent serious personal injury and possibledamage to components, be very careful whenusing lifting devices during service andmaintenance procedures.

• Inspect to make sure that neither lifting strap isdamaged.

• Do not subject lifting straps to any shock ordrop loading.

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

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

Figure 3.1


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

Planetary Spider Assembly


• Inspect to make sure that neither lifting strapis damaged.


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

2. With a lifting device, remove the planetary spiderassembly from the wheel hub and set it on aworkbench. Rest the spider with the large flangeending up.

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

4. [Figure 3.2] Place the planetary spider assemblyon blocks with the large flange end facing DOWN.Remove the spiral retaining ring by lifting exposedring end with a screw driver and spiraling ring outfrom slot in pins. If removal is not possible, the spiral retaining ring may be cut into sections.

!

WARNINGObserve all warnings and cautions provided bythe press manufacturer to avoid damage tocomponents and serious personal injury.

Use a brass or leather mallet for assembly anddisassembly procedures. Do not hit steel partswith a steel hammer. Pieces of a part can breakoff and cause serious personal injury.

CAUTIONTo avoid damage to the pinion shaft, provide asoft cushioned area to receive the pinion shaftwhen it is removed from the spider.

5. Use a press to remove the pinion shafts out ofthe spider. If a press is not available, use abrass drift and mallet to drive out the shaft.Press or drive the pinion shaft out toward thelarge flange end of the spider which facesDOWN.

6. Remove the planetary pinions and the thrustwasher from the planetary spider.

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

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

NOTE: The sun gear thrust washer may come outwith the axle shaft and sun gear assembly.

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

10. Remove the snap ring from the axle shaft toallow for the removal of the sun gear from theaxle shaft.

11. Remove the lock ring.

12. Remove the ring gear.

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Figure 3.2

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Figure 3.3

13. Remove the set screw from the spindle nut.

14. Remove the spindle nut.

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

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

CAUTIONDo not damage the hub oil seal bore surface inthe wheel hub. Damage to this surface will resultin oil leakage after assembly.

17. Remove the hub oil seal.

18. Remove the inner bearing cone.

19. If replacement of the wheel bearings isnecessary, press out the outer bearing cup andinner bearing cup.

20. Remove and discard the O-ring from the wheelhub.

Cam Brakes

To disassemble the PRC 485Q (with Q Plus™ cambrakes), refer to Maintenance Manual No. 4, CamBrakes. To order this publication, call ArvinMeritor’sCustomer Service Center at 800-535-5560.

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

!

Spindle and Brake Spider



• Do not subject lifting loops or lifting straps toany shock or drop loading.

Removal of the capscrews allows the spindle andbrake assembly to separate. They can fall fromthe planetary axle housing and cause damage tocomponents and serious personal injury.

1. To prevent the spindle and the brake spider fromfalling after all the mounting capscrews areremoved, use one of the following procedures:

A. Use a lifting device to support the spindleduring disassembly.

B. [Figure 3.3] Remove only two capscrews.Replace them with two temporary M16 x 2.0thread studs four inches (102 mm) long beforethe remaining capscrews are removed.

• Install one stud at the eleven o’clockposition.

• Install one stud at the one o’clock position.

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2. Remove the two capscrews and washers thatmount the clamp around the brake camshafthousing tube to the axle housing.

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

4. Remove the brake spider and air chamberassembly from the spindle.

5. Remove the spindle from the axle housing. Ifnecessary, tap lightly on the spindle to loosen thepilot fit and to overcome the adhesion due to thecured gasket material in the flange joint.

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


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PRC 485 W3H Wet Disc BrakeWheel End


Preliminary Disassembly



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PRC 485 W3H Wheel End Cross Section




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

WHEELSTUD

SUN GEARTHRUSTWASHER

THRUSTBUTTON

PLANETARYSPIDER

PLANETARYPINION SHAFT

MAGNETICDRAIN PLUG

RINGGEARWHEEL HUB

SPINDLE

AXLE SHAFT

OIL SEAL

WET BRAKEPISTON HOUSING WET BRAKE

DISC HOUSING

O-RING

LOCKRING

SUN GEAR

RING GEARHUB

O-RING

OUTERBEARING

INNERBEARING

SET SCREW

SPINDLENUT

FACE SEAL

SPIRAL RETAINING RING

SPACER

NEEDLEROLLERS

MACHINESCREW

WEARSLEEVE


PLANETARYGEAR

- 14 -









4. [Figure 3.4] Place the planetary spider assemblyon blocks with the large flange end facing DOWN.Remove the spiral retaining ring by lifting exposedring end with a screw driver and spiraling ring outfrom slot in pins. If removal is not possible, thespiral retaining ring may be cut into sections.



!

!CAUTION

To avoid damage to the pinion shaft, provide asoft cushioned area to receive the pinion shaftwhen it is removed from the spider.













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






!

!

Figure 3.4

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

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

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

8. Remove the washers and springs from the fourshoulder bolts. Push the piston from the pistonhousing. Use less than 20 psi (1.38 bar) airpressure. Insert three adjuster screws. Evenly turnthe screws CLOCKWISE.

Spindle and Piston Housing


• Inspect to make sure that neither lifting strap isdamaged.


Removal of the capscrews allows the spindle andpiston housing to separate. They can fall from theplanetary axle housing and cause damage tocomponents and serious personal injury.

1. To prevent the spindle and piston housing fromfalling after all the mounting capscrews areremoved, perform the following procedures:


!

- 15 -

Wheel End

Refer to Maintenance Manual MM-20195, Wet Disc Brake with Dowel Pins/Model W3H (360 mm).Call AxleTech’s Customer Service Center at 877-547-3407 to order this publication.

You can also access maintenance and productinformation on AxleTech’s web site. Refer to theService Notes page on the front inside cover of thismanual for instructions on how to access the site.

CAUTIONCare should be taken to store the (2) halves of theface seal to protect them from damage and savedfor reassembly later when required.

1. Remove the half TRS face seal from the hub. 2. Remove the remaining half of the face seal from

the brake disc assembly.

NOTE: Place the face seals together and store in asafe package to prevent damage.

WARNINGUse a brass or leather mallet for assembly anddisassembly procedures. Do not hit steel partswith a steel hammer. Pieces of a part can breakoff and cause serious personal injury.

3. Loosen sixteen M16 x 1.5 threaded capscrews. Hit the threaded capscrew heads with a mallet toseparate the wet disc brake housing.

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

CAUTIONDo not reuse a damaged friction disc or stationarydisc. Damage to components can result.

The friction discs and stationary discs are looseinside the brake housing assembly. Reachthrough the center of the brake housing and keepthe discs from falling out.

!

!

!


- 16 -

B. Remove only two capscrews. Replace themwith two temporary M20 x 2.5 thread studsfour inches (102 mm) long before theremaining capscrews are removed.



2. Remove the capscrews and washers that securethe piston housing and spindle to the axlehousing.

3. Remove the piston housing from the spindle.

4. [Figure 3.5] Remove the spindle from the axlehousing. If necessary, tap lightly on the spindle toloosen the pilot fit and to overcome the adhesiondue to the cured gasket material in the flangejoint.


Figure 3.5

Wet Disc Brakes




- 17 -

PRC 785P Planetary Axle Wheel End


Brake Drum



!




PRC 785P Wheel End Cross SectionINNERBEARING RING GEAR

SPINDLENUT

PLANETARYGEAR

O-RING

RINGGEARHUB

NEEDLEROLLERS

SPACER

SPIRALRETAININGRING

PLANETARYPINIONSHAFT


WHEELSTUD

WHEELHUB

SPINDLE

AXLE SHAFT

BRAKE DRUM

O-RING

OUTERBEARING

LOCK RINGOIL SEAL

SETSCREW

MACHINESCREW

WEARSLEEVE

MAGNETICDRAINPLUG

THRUSTBUTTON

PLANETARYSPIDER

SUN GEAR


- 18 -

6. If necessary, remove the magnetic drain plugfrom the bottom of the axle housing. Drain anddiscard the lubricant from the carrier centersection.

WARNINGWhen you work on a spring chamber, carefullyfollow the service instructions of the chambermanufacturer. Sudden release of a compressedspring can cause serious personal injury.

7. If the brake air chamber assembly has a springchamber unit, carefully cage and lock the springto prevent the spring from activating duringdisassembly.

NOTE: If Meritor automatic slack adjusters are used,refer to Maintenance Manual 4, Automatic SlackAdjuster, for the correct adjustment procedure. Toorder this publication, call ArvinMeritor’s CustomerService Center at 800-535-5560.

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




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

!

!

10. Install capscrews into the threaded holes in thebrake drum. Gradually tighten the capscrews inequal amounts to push the drum off the pilotsurface of the planetary spider.

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

Figure 3.6


- 19 -











!

!CAUTION




















!

!

Figure 3.7


- 20 -

Cam Brakes

To disassemble the P Series brake, refer toMaintenance Manual 4, Cam Brakes. To order thispublication, call ArvinMeritor’s Customer ServiceCenter at 800-535-5560.

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

Spindle and Brake Spider




WARNINGRemoval of the capscrews allows the spindle andbrake assembly to separate. They can fall fromthe planetary axle housing and cause damage tocomponents and serious personal injury.

1. To prevent the spindle and brake spider fromfalling after all the mounting capscrews areremoved, use one of the following procedures:


B. [Figure 3.8] Remove only two capscrews.Replace them with two temporary M20 x 2.5UNC thread studs four inches (102 mm) longbefore the remaining capscrews are removed.



!

!

2. Remove the two capscrews and washers thatmount the clamp around the brake camshafthousing tube to the axle housing.

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

4. Remove the brake spider and air chamberassembly from the spindle.

5. Remove the spindle from the axle housing. Ifnecessary, tap lightly on the spindle to loosen thepilot fit and to overcome the adhesion due to thecured gasket material in the flange joint.


Figure 3.8


- 21 -



Preliminary Disassembly



!




6. If necessary, remove the magnetic drain plugfrom the bottom of the axle housing. Drain anddiscard the lubricant from the carrier centersection.

PRC 785 W3H Wheel End Cross Section


THRUSTBUTTON

PLANETARYSPIDER

PLANETARYPINION SHAFT

MAGNETICDRAIN PLUG

PLANETARYGEAR

WHEELHUB

SPINDLE

AXLE SHAFT

OIL SEAL

WET BRAKEPISTON HOUSING WET BRAKE

DISC HOUSING

O-RING

LOCKRING

SUN GEAR

OUTERBEARING

INNERBEARING

SET SCREW

SPINDLENUT

WHEELSTUD

MACHINE SCREW

WEAR SLEEVE

FACE SEAL

SPIRALRETAINING RING

O-RING

RINGGEARHUB

NEEDLEROLLERS

SPACER

RINGGEAR


- 22 -












!

!CAUTION




















!

!

Figure 3.9

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

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

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

8. Remove the washers and springs from the fourshoulder bolts. Push the piston from the pistonhousing. Use less than 20 psi (1.38 bar) airpressure. Insert three adjuster screws. Evenly turnthe screws CLOCKWISE.

Spindle and Piston Housing




Removal of the capscrews allows the spindle andpiston housing to separate. They can fall from theplanetary axle housing and cause damage tocomponents and serious personal injury.

1. To prevent the spindle and piston housing fromfalling after all the mounting capscrews areremoved, perform the following procedures:


!

- 23 -

Wheel End



CAUTIONCare should be taken to store the (2) halves of theface seal to protect them from damage and savedfor reassembly later when required.

1. Remove the half TRS face seal from the hub.2. Remove the remaining half of the face seal from

the brake disc assembly.

NOTE: Place the face seals together and store in asafe package to prevent damage.


3. Loosen sixteen M16 x 1.5 threaded capscrews.Hit the threaded capscrew heads with a mallet toseparate the wet disc brake housing.

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



!

!

!


- 24 -

B. Remove only two capscrews. Replace themwith two temporary M20 x 2.5 thread studs fourinches (102 mm) long before the remainingcapscrews are removed.



2. Remove the capscrews and washers that securethe piston housing and spindle to the axlehousing.

3. Remove the piston housing from the spindle.

4. [Figure 3.10] Remove the spindle from the axlehousing. If necessary, tap lightly on the spindle toloosen the pilot fit and to overcome the adhesiondue to the cured gasket material in the flangejoint.


Wet Disc Brakes



Figure 3.10


- 25 -


Clean Ground or PolishedParts

WARNINGSolvent cleaners can be flammable, poisonousand cause burns. Examples of solvent cleanersare carbon tetrachloride, emulsion-type cleanersand petroleum-based cleaners. To avoid seriouspersonal injury when you use solvent cleaners,you must carefully follow the manufacturer’sproduct instructions and these procedures:

• Wear safe eye protection.

• Wear clothing that protects your skin.

• Work in a well-ventilated area.

• Do not use gasoline or solvents that containgasoline. Gasoline can explode.

• You must use hot solution tanks or alkalinesolutions correctly. Follow the manufacturer’sinstructions carefully.

CAUTION• Use only solvent cleaners to clean

ground or polished metal parts. Hotsolution tanks or water and alkalinesolutions will damage these parts.Isopropyl alcohol, kerosene or dieselfuel can be used for this purpose.

• If required, use a sharp knife to remove gasketmaterial from parts. Be careful not to damagethe ground or polished surfaces.

1. Use a cleaning solvent, kerosene or diesel fuel, toclean ground or polished parts or surfaces.NEVER USE GASOLINE.

2. Remove gasket material from parts. Take care notto damage ground surfaces.

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

!

!

! Clean Parts with a Rough Finish1. Use a cleaning solvent or a hot solution tank with

a weak alkaline solution to clean parts with arough finish.

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

3. Wash the parts with water until you completelyremove the alkaline solution.

Clean Axle Assemblies• A complete axle assembly can be steam cleaned

on the outside to remove dirt.

• Before the axle is steam cleaned, close or put acover over all the openings in the axle assembly.Examples of openings are the breathers or ventsin air chambers.

CAUTIONDry bearings with clean paper or rags. Do notuse compressed air, which can cause abrasiveparticles to contaminate the bearings. Damage tocomponents and reduced lining life can result.

Dry Cleaned Parts• Immediately after cleaning, use clean paper, rags

or compressed air to dry parts.

Prevent CorrosionNOTE: Parts must be clean and dry before youlubricate them.

1. If you assemble the parts immediately afteryou clean them: Lubricate the clean, dry partswith grease to prevent corrosion.

2. If you store the parts after you clean them:Apply a corrosion-preventive material to allmachined surfaces. Store the parts in a specialpaper or other material that prevents corrosion.

!

Section 4Prepare Parts for Assembly

- 26 -

Inspect Parts• It is important to carefully inspect all parts for

wear and damage before you assemble the axlecarrier.

• Replace damaged parts.

Inspect Tapered Roller Bearings

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

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

• [Figure 4.1] The centers of the large diameterend of the rollers are worn to a sharp edge.

• [Figure 4.2] A visible roller groove is worn in thecup or cone inner race surfaces. You can see thegroove at the small or large diameter ends of bothparts.

Figure 4.2

Figure 4.1WORN RADIUS

WORN SURFACE

CRACK WEAR GROOVES


- 27 -

• [Figure 4.5] Spalling or flaking is present on thecup and cone inner race surfaces that touch therollers.

Inspect the Bevel Pinion and RingGear Sets

CAUTIONThe bevel drive pinions and ring gears aremachined in matched sets. When a drive pinion orring gear of a bevel set needs to be replaced, bothdrive gear and pinion must be replaced at thesame time. A higher stress on the original partsand early failure of the entire assembly will resultif a new part is used in combination with partsthat are older or worn.

1. Inspect the bevel drive pinions and ring gears forwear and damage. Gears that are worn ordamaged must be replaced.

2. Verify the condition of the bearing cone seats andspline on the pinion shaft.

!

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

• [Figure 4.3] Bright wear marks are present on theouter surface of the roller cage.

• [Figure 4.4] Etching and pitting is present on therollers and on surfaces of the cup and cone innerrace that touches the rollers.

Figure 4.5 SPALLING ANDFLAKING

Figure 4.3

Figure 4.4

WEAR MARKS

ETCHING ANDPITTING


- 28 -

Inspect the Main DifferentialAssembly

1. Use a cleaning solvent, kerosene or diesel fuel, toclean the interior of the main differentialassembly. NEVER USE GASOLINE.

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

3. Observe the side gear and differential pinionsduring rotation. Replace the differential assemblyif you see chipped or broken teeth, or if there aredamaged cases.

Inspect the Axle Shafts

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

Inspect the Yoke

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

Inspect the Brakes



Repair or Replace PartsReplace the worn or damaged parts of an axleassembly. The following are some examples tocheck for repair and possible replacement:

• Replace any fastener if corners of the head areworn.

• Replace washers if damaged.

• Replace gaskets, oil seals or grease seals at thetime of axle repair.

• Clean parts and apply new liquid gasket materialwhere required when the axle is assembled.

• Remove nicks, marks and burrs from parts havingmachined or ground surfaces. Use a fine file, Indiastone, emery cloth or crocus cloth for thispurpose.

• Clean and repair the threads of fasteners andholes. Use a die or tap of the correct size or a finefile for this purpose.

• Tighten all fasteners to the correct torque values.Refer to chart in Section 6 for fastener torquevalues.

Repair Welding

WARNINGDo not weld repair, heat, bend or recondition axlecomponents. This will reduce componentstrength, void AxleTech’s warranty, and canresult in serious personal injury and damage tocomponents. Always replace damaged or out-of-specification components.

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

!

T


- 29 -

5. Assemble the components immediately to permit thegasket material to compress evenly between parts.Tighten the fasteners to the required torque value forthat size fastener using an “X” torquing pattern.Refer to the Torque Chart in Section 6.

6. Wait 20 minutes before filling the assembly withlubricant.

Apply Silicone Gasket Material(All Specs Spindle To HousingJoint) AxleTech Specifications:

• ThreeBond 1216

• Loctite 5699

WARNINGWhen you apply some silicone gasket materials,small amounts of acid vapor are present. Toprevent possible serious injury, the work areamust be well-ventilated. If the silicone gasketmaterial gets into your eyes, flush them withwater for 15 minutes. Have your eyes checked bya doctor as soon as possible.

1. Remove all the old gasket material from the surfacesof both components.

2. Clean the surfaces where the liquid gasket materialwill be applied. Remove all the oil, grease, dirt andmoisture.

3. Thoroughly dry both surfaces.

CAUTIONThe amount of liquid gasket material applied tocomponent surface must not exceed 0.125 inch(3.18 mm) diameter bead. Too much gasketmaterial can block lubrication passages. Damageto components can result.

4. [Figure 4.6] Apply a 0.125 inch (3.18 mm) diametercontinuous bead of silicone gasket material aroundone surface. Also apply the gasket material aroundthe edge of all the fastener holes on that surface.

!

!

Figure 4.6

0.125" (3.18 MM)DIAMETER SILICONEGASKET MATERIAL BEAD


- 30 -


PRC 485Q (with Q Plus™ CamBrakes) Planetary Axle Wheel End

Prepare Parts for AssemblyNOTE: Refer to Section 4, “Prepare Parts forAssembly.”

Spindle, Brake Spider and Brake

1. [Figure 5.1] Install two temporary studs (M16 - 2.0 threads, approximately four incheslong) into the axle housing flange. Install thestuds at the eleven o’clock and one o’clockpositions.

2. If wear sleeve was removed, reinstall by applyingLoctite 518 to the wear sleeve ID and press it ontothe spindle using driver tool 0978530003.

! WARNINGWhen you apply some silicone gasket materials,small amounts of acid vapor are present. Toprevent possible serious injury, the work areamust be well-ventilated. If the silicone gasketmaterial gets into your eyes, flush them withwater for 15 minutes. Have your eyes checked bya doctor as soon as possible.

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

4. Install the spindle onto the axle housing.

5. Install the brake spider onto the spindle.

6. Install and hand tighten some of the spindlemounting capscrews and washers.

7. Remove the two temporary studs.

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

!

Figure 5.1

Figure 5.2

GASKETMATERIAL

Section 5Assembly

- 31 -

NOTE: Replace the camshaft bushing and greaseseals before the camshaft bracket is installed ontothe brake spider. Refer to Maintenance Manual 4,Cam Brakes. To order this publication, callArvinMeritor’s Customer Service Center at 800-535-5560.

9. Install the brake camshaft bracket with the O-ring on the pilot onto the brake spider.

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

NOTE: Refer to Maintenance Manual 4, CamBrakes; and Automatic Slack Adjuster, to install thebrake camshaft, anchor pin components, brakeshoes, brake springs, slack adjusters and relatedparts. To order this publication, call ArvinMeritor’sCustomer Service Center at 800-535-5560.

11. Install the brake camshaft bracket clamp aroundthe bracket tube. Install the two capscrews andwashers that mount the clamp to the axlehousing. See "Torque Table" in section 6.

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

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

14. Install the brake dust shield. Tighten themounting capscrews and washers. See "Torque Table" in section 6.

Wheel End

1. Press the new inner and outer bearing cups intothe wheel hub using 0979541000 and0979540000 tool drivers.

2. Position the wheel hub with the oil seal borefacing UP.

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

CAUTION• Do not damage the hub oil seal bore

surface in the wheel hub. Damage to thissurface will result in oil leakage afterassembly.

NOTE: Use a Permatex coating to seal against leaksaround the hub oil seal. Leaks would result inrequiring disassembly, should leak be noted after thefinal axle assembly.

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

5. [Figure 5.3] Use the oil seal driver 0979542000 toinstall the wheel hub oil seal. See figure for properseal orientation. Press the seal into the hub untilthe seal face is flush with the hub face.

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

7. Install the wheel hub, inner bearing and oil sealassembly onto the spindle. Keep the hub assemblyaligned with the spindle.

!

Figure 5.3

Section 5Assembly

- 32 -

8. Apply axle lubricant to the outer bearing conerollers. Install the outer bearing cone onto the ringgear hub.

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

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

11. Install the wheel bearing adjusting nut.

Adjust the Wheel Bearing Preload

NOTE: To adjust the wheel bearing preload, thebearings must be seated and the rollers in properalignment.


1. Install the wheel bearing adjusting nut. See"Torque Table" in section 6.

2. Rotate the hub in bothdirections. At the same time, tap the hub severaltimes with a brass or plastic mallet.

3. Tighten the nut using the spindle nut tool0979534000. Tighten further until one of the nut’sscallops lines-up with one of the threaded holes inthe ring hub. See special tool section. See"Torque Table" in section 6.

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

5. Install the set screw.

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

!

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

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

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

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

• The axle shaft must make engagement with thedifferential side gear.

• The sun gear must make contact with the thrustwasher.

• Insure washer tangs are keyed into the spindlenut slots.

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

Planetary Spider and Gearing Assembly

WARNINGWhen you apply some silicone gasket materials,small amounts of acid vapor are present. Toprevent possible serious injury, the work areamust be well ventilated. If the silicone gasketmaterial gets into your eyes, flush them withwater for 15 minutes. Have your eyes checked bya doctor as soon as possible.

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

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

!

Section 5Assembly

- 33 -

3. Make the planet gear subassemblies.A. Put a planet shaft standing with the big

shoulder flange down.

B. Apply gear lubricant.

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

D. Insert the planet gear on the planet shaft suchas the rollers end up between the planet shaftOD and planet gear ID with the grooved faceof planet gear down against shaft flange.

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

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

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

5. Install the big thrust washer.

6. Install the corresponding O-rings into each planetgears subassembly.

7. Align the spider with the planet gearssubassemblies and with the flange down.

8. Press the spider into the planet gearssubassemblies until the planet gearssubassemblies are flush with the end of thespider.

9. [Figure 5.4] Install the spiral retaining ring byfeeding one end of the ring into the slots in theplanet pins.

Final Assembly

NOTE: For correct installation, the planetary pinionsmust engage both the sun gear and the ring gearbefore installation.

1. Install the planetary spider and gearing assemblyonto the wheel hub.

2. Install the three slotted head machine screws thatattach the planetary spider to the wheel hub.Tighten the screws, compressing o-ring until nogap exists between wheel hub flange and spiderflange.

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

4. Mount the inner and outer wheels. Install thewheel nuts and tighten them to the vehiclemanufacturer’s specification.

NOTE: The PRC 485Q (with Q Plus™ Cam Brakes)axle has a common oil level between the carrier andthe wheel ends. Three locations must be filled. Thevehicle must be on a level surface when filling. Fill tothe bottom of each fill plughole. Wait and allow the oilto flow through the axle. Check the oil level againafter several minutes and fill to the specified level ifnecessary.

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

6. Add the correct lubricant to the axle housing bowlarea.

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

8. Install the fill/level plugs and tighten to 35 lb-ft (47 N•m).

Figure 5.4

Section 5Assembly

- 34 -



Spindle and Piston Housing to the Axle Housing1. [Figure 5.5] Install two temporary studs (M20 x

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


WARNINGTake care when using Loctite® to avoid seriouspersonal injury. Follow the manufacturer’sinstructions to prevent irritation to the eyes andskin. If Loctite gets into your eyes, flush themwith water for 15 minutes. Have your eyeschecked by a doctor as soon as possible.

NOTE: The piston housing has TOP identified by araised lug.

3. Clean and inspect the spindle and piston housingfor damage. Apply a small, two millimeter bead ofQ48 (Loctite 518) near the OD of the spindleflange and around each bolt hole, on both sides ofthe spindle flange.

4. Mount the spindle and piston housing (lug onTOP) onto the axle housing using thirteen M20 x 2.5 thread capscrews. Tighten thecapscrews in an “X” torquing pattern to achieve370-480 lb-ft (500-650 N•m) bolt torque.

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

Wet Disc Brakes

To assemble the PRC 485 W3H wet disc brakes,refer to Maintenance Manual MM-20195, 360 mmWet Disc Brakes. To order this publication, callAxleTech International Customer Service Center at 877-547-3907.

NOTE: To continue assembling the PRC 485 W3Hwet disc brake wheel end, continue with the followingsteps.

!

Figure 5.5

Section 5Assembly

- 35 -

Wheel End1. Clean and inspect the piston for damage, inspect

the piston grooves to ensure no contaminantsremain in the grooves.

2. Apply an oil lubricant to the “D” seals andassemble the “D” seals into the appropriategrooves in the piston.


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

NOTE: The piston slightly sticks out of the pistonhousing.

4. Remove and store the four assembly studs.

5. Install washers and springs on the four shoulderbolts.

6. Apply a small bead of Loctite 518 to the fourshoulder bolt threads and install the four shoulderbolts into the piston and piston housing. Tightenthe four shoulder bolts to 22-30 lb-ft (30-40 N•m).

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

NOTE: The brake housing has TOP identified with araised lug.

8. Place the brake housing on an assembly bench.Assemble the eight dowels into the slots in thebrake housing.

!

CAUTIONDo not reuse a damaged friction disc orstationary disc. Damage to components canresult.

The friction discs and stationary discs are looseinside the brake housing assembly. Reachthrough the center of the brake housing and keep the discs from falling out.

9. Line up all the friction disc splines and grooves ina stack so that they can be assembled this wayinside the brake housing.

10. Place a friction disc inside the brake housing.Place a stationary disc into the brake housingwhile engaging all the dowels in the disc’s slots.

11. Repeat these steps until completing the assemblystack of discs. Realign all the friction discs’ splinesand grooves.


12. Apply a small, continuous two millimeter bead ofLoctite 518 onto the mounting face of the brakehousing and around each bolt hole. Carefully liftthe brake housing assembly (lug on TOP) andinstall it onto the piston housing that is alreadymounted on the axle.

13. Tighten sixteen M16 x 1.5 threaded capscrews inan “X” torquing pattern to achieve 200-258 lb-ft(270-350 N•m) bolt torque.

!

!

Section 5Assembly

22. Refer to Toric Ring Face Seal into Wheel Huband Disc Brake Housing, page 37, to install thesecond half of the toric face seal into the hub andcup assembly by using tool 860901002T toproperly position the O-ring and steel ringassembly beyond the lip and into the taperedbore in the hub. See Special Tool Section 7,Figure 7.3.

23. Measure the height of the metal face above thehousing to ensure the tolerance is within 1 mmvariation.

CAUTIONDo not apply lubricant to the O-ring. Damage andleaks will result.

24. Apply a light coating of lubricant to the two matingsurfaces of the face seal’s steel rings only. Do notallow the lubricant to contact the O-ring. Use thesame lubricant that was used on the coolant side.

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

26. Install the hub with the brake driver splinesthrough the friction discs.

27. Install the outer bearing cone on the spindle.Install the spindle nut on the spindle. Rotate thehub while tightening the nut as recommended inAdjust the Wheel Bearing Preload section.

!

- 36 -

NOTE: Use isopropyl alcohol to lubricate the O-ringimmediately before this installation of the face seal.

14. Refer to Toric Ring Face Seal into Wheel Huband Disc Brake Housing, page 37, to install halfof the TRS face seal into the brake housing byusing tool 860901002T to properly position theO-ring and steel ring assembly beyond the lipand into the tapered bore in the brake housing.See Special Tool Section 7, Figure 7.3.

15. Measure the height of the metal face above thehousing to ensure the tolerance is within 1 mmvariation.

16. Clean and inspect the hub.




NOTE: Use a Permatex coating to seal against leaksaround the hub oil seal. Leaks would result inrequiring disassembly, should the leak be noted afterthe final axle assembly.


21. [Figure 5.6] Use the oil seal driver 0979542000to install the wheel hub oil seal. See figure forproper seal orientation. Press the seal into thehub until the seal face is flush with the shoulderin the hub bore.

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

Section 5Assembly

Figure 5.6

- 37 -

Section 5Assembly

1. Seal Ring 5. Seal Ring Housing

2. Toric Ring 6. Seal Ring Face

3. Housing Retainer Lip 7. Installation Tool (TC-79461)

4. Housing Ramp

Figure 5.7

1 2

3

4

5

7

6

Toric Ring Face Seal into WheelHub and Disc Brake Housing

CAUTIONInstall face seal halves in the same positionswhere they were located prior to disassembly.Mixing up face seal halves can cause componentdamage.

[Figure 5.7] The TRS Toric Ring Face seal half mustbe installed in the hub before the hub can beassembled to the spindle. Install the Toric Ring Faceseal half in the hub as follows:

!

WARNINGSolvent cleaners can be flammable, poisonousand cause burns. Examples of solvent cleanersare carbon tetrachloride, emulsion-type cleanersand petroleum-base cleaners. To avoid seriouspersonal injury when you use solvent cleaners,you must carefully follow the manufacturer’sinstructions and these procedures:




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

• You must use hot solution tanks or alkalinesolutions correctly. Carefully follow themanufacturer’s instructions.

CAUTIONCheck for solvent residue on all seating surfaces.Solvents that leave a residue on the Toric Ring,metal face seal or on housing seal seatingsurface can cause the Toric Ring to roll into theseal, rather than slide. Damage to the seal can result.

1. Make sure the formed seal ring, Toric Ring andwheel hub are clean and free of any oil or othercontaminants. If required, use a solvent likeisopropyl alcohol, that evaporates quickly, leavesno residue, and is compatible with the Toric Ring.

CAUTIONInstall the Toric Ring into the seal ring and makesure it is flat. Do not twist the Toric Ring wheninstalling onto the seal ring. A twisted Toric Ringwill not seal correctly, allowing leakage oflubricant and pumping of debris past the ring.Damage to components can result.

2. Install the Toric Ring onto the formed seal ring sothat it rests in the radius of the tail of the seal ringand is not twisted. Install the Toric Ring onto theseal ring as follows:

!

!

!

- 38 -

Section 5Assembly

CAUTIONDo not use Stanosol® or any other liquid thatleaves an oily film and does not evaporate quickly,since this may result in incorrect seating of the O-ring in the housing, resulting in seal leakage.

3. [Figure 5.10] Coat the Toric Ring with isopropylalcohol so that it slides easily past the retainer lipin the wheel hub and installs correctly on thespindle ramp.

4. Place installation tool part number TC-79461 (seeSpecial Tool Section) around the metal seal ringand Toric Ring. Installation tools are availablefrom AxleTech International at in North America 1-877-547-3907, in Europe 33-477-92-8868 or at www.axletech.com/aftermarket.htm.

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

6. [Figure 5.10] Shake excess lubricant from theassembly. Immediately install (“pop”) the seal intothe wheel hub with a firm push of the installationtool.

7. Remove the installation tool.

!

Figure 5.10

CAUTIONDo not use Stanosol® or any other liquid thatleaves an oily film and does not evaporatequickly, since this may result in incorrect seatingof the Toric Ring in the housing, resulting in sealleakage.

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

B. [Figure 5.9] Make sure the Toric Ring is nottwisted by rapidly pulling it away from the sealring and letting it snap back. Do this in anumber of places until the seal is correctlyseated. Be careful not to nick or cut the ToricRing seal, as this will cause leaks.

!

1. Seal Ring Ramp 3. Seal Ring Retaining Lip

2. Rubber Toric Ring 4. Seal Ring

Figure 5.8

4

3

1

2

Figure 5.9

- 39 -

Section 5Assembly

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

• If the standout height cannot be brought intospecification: Remove the seal and repeat theinstallation procedure.

CAUTIONPush or pull the Toric Ring and face seal only. Donot push or pull directly on the seal ring. Thiscan cause component damage.

A. Use the installation tool to push down on theToric Ring and face seal.

B. With your fingers, pull up uniformly on theToric Ring and face seal.

CAUTIONApply isopropyl alcohol to the Toric Ring. Checkthe retaining lip of the seal seating area for burrsor fins, which can cause a seal to leak. Damageto components can result.

3. Apply isopropyl alcohol as a lubricant to the ToricRing and place in the seating area. If installationdoes not appear smooth, flat and correct, removethe seal from the spindle and repeat the process.

CAUTIONTo prevent slippage of the Toric Ring, allowsufficient evaporation time for the assemblylubricant before proceeding with furtherassembly. Damage to components can result.

4. [Figure 5.13] Seat Toric Ring correctly. Oncecorrectly in place, the Toric Ring must roll onramp only.

!

!

!

Figure 5.13

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

Check for Correct Installation of the TRS Toric Ring Seal

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

1. [Figure 5.12] Check assembled height variation(A) in at least four places, 90 degrees apart, usinga caliper, toolmaker’s rule, or other accuratelycalibrated measuring device. The difference inheight around the ring must not be more than 0.5mm (0.02 inch).

Figure 5.12

Figure 5.11

- 40 -

Section 5Assembly

• If the seals are not aligned correctly: Theseals will move. Any wobbling motion of theseals is an indication of incorrectly positioned(cocked) seals. Dirt can enter past the ToricRing.

• [Figure 5.15] The Toric Rings have slipped,instead of rolling on the left-hand side of theseal. Note how the top Toric Ring is to the rightand the bottom Toric Ring is to the left. Thesame seals are also shown after the bottom halfis rotated 90 degrees.

• If the Toric Ring slips at any location, it willtwist, causing the formed seal rings to seatincorrectly (cock).

Figure 5.15

Wheel Hub to Spindle Assembly

NOTE: Complete the assembly of the wheel hub tothe spindle. Before installing the wheel hub onto thespindle, however, keep the following points in mind toensure correct sealing between the faces of the ToricRing:

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

CAUTIONBring the housings together slowly. High impactcan result in component damage. Removeprotective pad from the spindle's seal journal.

2. Remove the protective pad from the spindle's sealjournal.

CAUTIONDo not apply lubricant to the Toric Ring. The ToricRing can leak. Damage to components can result.

3. Apply a light coating of Dow Corning GNmolybdenum assembly paste lubricant to the twomating surfaces of the face seal’s steel rings only.Do not allow this lubricant to contact the ToricRing. The Toric Ring can leak. Figure 4.25.

• When installing the hub onto the spindle, both sealhousings must be aligned correctly.

• [Figure 5.14] Slowly bring the hub and spindleassembly together as the spindle bearingadjustment nut is tightened.

!

!

Figure 5.14

FACE SEALMATINGSURFACES

- 41 -

Section 5Assembly







B. apply gear lubricant.

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

D. Insert the planet gear on the planet shaft suchas the rollers end up between the planet shaftOD and planet gear ID with the grooved faceof planet gear down against shaft flange.




5. Install the thrust washer.

6. Install the corresponding O-rings into each planetgears subassembly



!





2. Rotate the hub in bothdirections. At the same time, tap the hub severaltimes with a brass or plastic mallet.



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



8. Apply a thin layer of axle grease to the face of thesun gear thrust washer.








!

- 42 -

Section 5Assembly


Final Assembly









Fill Wet Disc Brakes with Hydraulic Fluid

1. Fill the wet disc brakes with tractor oil universal(TOU) fluid by using the 0.875"-14 UNFO-ring plug near the top of the brake and a 0.875"-14 UNF O-ring plug above the three or nine o’clockposition. Fill the brakes until oil exits the lower plug(above the three or nine o’clock position). Installthe lower plug and add two more liters of oilthrough the top plug.

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

NOTE: Brake coolant inlet is connected to the 0.875"-14 UNF O-ring plug at the top position of the brakebetween the mounting bolts. The brake actuation lineis connected at the 0.5625"-18 UNF plug at either thethree or nine o’clock position.

3. Thoroughly bleed all the air from the brakeactuation system.

4. Preform pressure test on brake apply circuit.

Figure 5.16

- 43 -

Section 5Assembly


3. Apply a 0.125 inch (3.18 mm) diameter continuousbead of silicone gasket material around the flangemounting face of either the axle housing or thespindle. Also apply the gasket material around theedge of all the fastener holes on that surface.

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

5. Install the brake spider onto the spindle.

6. Install and hand tighten some of the spindlemounting capscrews and washers.

7. Remove the two temporary studs.

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

!PRC 785P Planetary Axle Wheel End


Spindle, Brake Spider and Brake


1. [Figure 5.17] Install two temporary studs (M20 -2.5 threads, approximately four inches long) intothe axle housing flange. Install the studs at theeleven o’clock and one o’clock positions.


!

Figure 5.17

Figure 5.18

GASKETMATERIAL

- 44 -

Section 5Assembly

NOTE: Replace the camshaft bushing and greaseseals before the camshaft bracket is installed ontothe brake spider. Refer to Maintenance Manual 4,Cam Brakes. To order this publication, callAxleTech’s Customer Service Center at 877-547-3907.

8. Install the brake camshaft bracket with the O-ring on the pilot onto the brake spider.

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

NOTE: Refer to Maintenance Manual 4, CamBrakes; and Automatic Slack Adjuster, to install thebrake camshaft, anchor pin components, brakeshoes, brake springs, slack adjusters and relatedparts. To order this publication, call AxleTech’sCustomer Service Center at 877-547-3907.

10. Install the brake camshaft bracket clamp aroundthe bracket tube. Install the two capscrews andwashers that mount the clamp to the axlehousing. See "Torque Table" in section 6.

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

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

13. Install the brake dust shield. Tighten themounting capscrews and washers to 35-50 lb-ft (47-68 N•m).

Wheel End




CAUTION• Do not damage the hub oil seal bore

surface in the wheel hub. Damage to thissurface will result in oil leakage afterassembly.

NOTE: Use a Permatex coating to seal against leaksaround the hub oil seal. Leaks would result inrequiring disassembly, should leak be noted after thefinal axle assembly.


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

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

7. Install the wheel hub, inner bearing and oil sealassembly onto the spindle. Keep the hub assemblyaligned with the spindle.

!

Figure 5.19

- 45 -

Section 5Assembly

8. Apply axle lubricant to the outer bearing conerollers. Install the outer bearing cone onto the ringgear hub.

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

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

11. Install the wheel bearing adjusting nut.





2. Rotate the hub in both directions. At the sametime, tap the hub several times with a brass orplastic mallet.






!

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












!

- 46 -

Section 5Assembly





D. Insert the planet gear on the planet shaft suchas the rollers end up between the planet shaftOD and planet gear ID with the grooved faceof the planet gear down against the shaftflange.




5. Install the thrust washer

6. Install the corresponding O-rings into each planetgears subassembly




Final Assembly




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


NOTE: The PRC 785P axle has a common oil levelbetween the carrier and the wheel ends. Threelocations must be filled. The vehicle must be on alevel surface when filling. Fill to the bottom of each fillplughole. Wait and allow the oil to flow through theaxle. Check the oil level again after several minutesand fill to the specified level if necessary.





Figure 5.20

- 47 -

Section 5Assembly

3. Clean and inspect the spindle and piston housingfor damage. Apply a small, two millimeter bead ofLoctite 518 near the OD of the spindle flange andaround each bolt hole, on both sides of the spindle flange.

4. Mount the spindle and piston housing (lug on TOP)onto the axle housing using thirteen M20 x 2.5thread capscrews. Tighten the capscrews in an “X”torquing pattern to achieve 370-480 lb-ft (500-650N•m) bolt torque.

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

Wet Disc Brakes

To assemble the PRC 785 W3H wet disc brakes,refer to Maintenance Manual MM-20195, 360 mmWet Disc Brakes. To order this publication, callAxleTech’s Customer Service Center at 877-547-3907.

NOTE: To continue assembling the PRC 785 W3H wet disc brake wheel end, continue with the followingsteps.

Wheel End

1. Clean and inspect the piston for damage, inspectthe piston grooves to ensure no contaminantsremain in the grooves.

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


NOTE: The piston slightly sticks out of the pistonhousing.

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

!



Spindle and Piston Housing to the Axle Housing1. [Figure 5.21] Install two temporary studs

(M20 x 2.5 threads, approximately four incheslong) into the axle housing flange. Install the studsat the eleven o’clock and one o’clock positions.



NOTE: The piston housing has TOP identified by araised lug.

!

Figure 5.21

- 48 -

Section 5Assembly

4. Remove and store the four assembly studs.

5. Install washers and springs on the four shoulderbolts.

6. Apply a small bead of Loctite 518 to the fourshoulder bolt threads and install the four shoulder bolts into the piston and piston housing. Tighten the four shoulder bolts to 22-30 lb-ft (30-40 N•m).

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

NOTE: The brake housing has TOP identified with araised lug.

8. Place the brake housing on an assembly bench.Assemble the eight dowels into the slots in thebrake housing.



9. Line up all the friction disc splines and grooves ina stack so that they can be assembled this wayinside the brake housing.

10. Place a friction disc inside the brake housing.Place a stationary disc into the brake housingwhile engaging all the dowels in the disc’s slots.

11. Repeat these steps until completing the assemblystack of discs. Realign all the friction disc splinesand grooves.


12. Apply a small, continuous two millimeter bead ofLoctite 518 onto the mounting face of the brakehousing and a round each bolt hole. Carefully liftthe brake housing assembly (lug on TOP) andinstall it onto the piston housing that is alreadymounted on the axle.

13. Tighten sixteen M16 x 1.5 threaded capscrews inan “X” torquing pattern to achieve 200-258 lb-ft(270-350 N•m) bolt torque.

!

!

NOTE: Use isopropyl alcohol to lubricate O-ringimmediately before this installation of the face seal.

14. Refer to Toric Ring Face Seal into Wheel Huband Disc Brake Housing, page 49, to install halfof the TRS face seal into the brake housing byusing tool 860901002T to properly position theO-ring and steel ring assembly beyond the lipand into the tapered bore in the brake housing.See Special Tool Section 7, Figure 7.3.

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

16. Clean and inspect the hub.




NOTE: Use a Permatex coating to seal against leaksaround the hub oil seal. Leaks would result inrequiring disassembly, should the leak be noted afterthe final axle assembly.


21 [Figure 5.22] Use the oil seal driver 0979542000to install the wheel hub oil seal. See figure forproper seal orientation. Press the seal into thehub until the seal face is flush with the shoulderin the hub bore.

NOTE: Use isopropyl alcohol to lubricate O-ringimmediately before this installation.

Figure 5.22

- 49 -

Section 5Assembly

22. Refer to Toric Ring Face Seal into Wheel Huband Disc Brake Housing, page 49, to install thesecond half of the toric face seal into the hub andcup assembly by using tool 860901002T toproperly position the O-ring and steel ringassembly beyond the lip and into the taperedbore in the hub. See Special Tool Section 7,Figure 7.3.

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

CAUTIONDo not apply lubricant to the O-ring. Damage andleaks will result.

24. Apply a light coating of lubricant to the two matingsurfaces of the face seal’s steel rings only. Do notallow lubricant to contact the O-ring. Use thesame lubricant that was used on the coolant side.

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

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

27. Install the outer bearing cone on the spindle.Install the spindle nut on the spindle. Rotate thehub while tightening the nut as recommended inAdjust the Wheel Bearing Preload section.

Toric Ring Face Seal into WheelHub and Disc Brake Housing

CAUTIONInstall face seal halves in the same positionswhere they were located prior to disassembly.Mixing up face seal halves can cause componentdamage.

[Figure 5.23] The TRS Toric Ring Face seal halfmust be installed in the hub before the hub can beassembled to the spindle. Install the Toric Ring Faceseal half in the hub as follows:

!

!

WARNINGSolvent cleaners can be flammable, poisonousand cause burns. Examples of solvent cleanersare carbon tetrachloride, emulsion-type cleanersand petroleum-base cleaners. To avoid seriouspersonal injury when you use solvent cleaners,you must carefully follow the manufacturer’sinstructions and these procedures:




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

• You must use hot solution tanks or alkalinesolutions correctly. Carefully follow themanufacturer’s instructions.

CAUTIONCheck for solvent residue on all seating surfaces.Solvents that leave a residue on the Toric Ring,metal face seal or on housing seal seating surfacecan cause the Toric Ring to roll into the seal,rather than slide. Damage to the seal can result.

1. Make sure the formed seal ring, Toric Ring andwheel hub are clean and free of any oil or othercontaminants. If required, use a solvent likeisopropyl alcohol, that evaporates quickly, leavesno residue, and is compatible with the Toric Ring.

!

!

1. Seal Ring 5. Seal Ring Housing

2. Toric Ring 6. Seal Ring Face

3. Housing Retainer Lip 7. Installation Tool (TC-79461)

4. Housing Ramp

Figure 5.23

1 2

3

4

5

7

6

- 50 -

Section 5Assembly

CAUTIONInstall the Toric Ring into the seal ring and makesure it is flat. Do not twist the Toric Ring wheninstalling onto the seal ring. A twisted Toric Ringwill not seal correctly, allowing leakage oflubricant and pumping of debris past the ring.Damage to components can result.

2. Install the Toric Ring onto the formed seal ring sothat it rests in the radius of the tail of the seal ringand is not twisted. Install the Toric Ring onto theseal ring as follows:

CAUTIONDo not use Stanosol® or any other liquid thatleaves an oily film and does not evaporatequickly, since this may result in incorrect seatingof the Toric Ring in the housing, resulting in sealleakage.

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

B. [Figure 5.25] Make sure the Toric Ring is nottwisted by rapidly pulling it away from the sealring and letting it snap back. Do this in anumber of places until the seal is correctlyseated. Be careful not to nick or cut the ToricRing seal, as this will cause leaks.

!

!

CAUTIONDo not use Stanosol® or any other liquid thatleaves an oily film and does not evaporate quickly,since this may result in incorrect seating of the O-ring in the housing, resulting in seal leakage.

3. [Figure 5.26] Coat the Toric Ring with isopropylalcohol so that it slides easily past the retainer lipin the wheel hub and installs correctly on thespindle ramp.

4. Place installation tool part number TC-79461 (seeSpecial Tool Section) around the metal seal ringand Toric Ring. Installation tools are availablefrom AxleTech International at in North America 1-877-547-3907, in Europe 33-477-92-8868 or at www.axletech.com/aftermarket.htm.

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

6. [Figure 5.26] Shake excess lubricant from theassembly. Immediately install (“pop”) the seal intothe wheel hub with a firm push of the installationtool.

!

Figure 5.26

1. Seal Ring Ramp 3. Seal Ring Retaining Lip

2. Rubber Toric Ring 4. Seal Ring

Figure 5.24

4

3

1

2

Figure 5.25

- 51 -

Section 5Assembly

7. Remove the installation tool.

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

Check for Correct Installation of the TRS Toric Ring Seal

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

1. [Figure 5.28] Check assembled height variation(A) in at least four places, 90 degrees apart, usinga caliper, toolmaker’s rule, or other accuratelycalibrated measuring device. The difference inheight around the ring must not be more than 0.5mm (0.02 inch).

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

• If the standout height cannot be brought intospecification: Remove the seal and repeat theinstallation procedure.

CAUTIONPush or pull the Toric Ring and face seal only. Donot push or pull directly on the seal ring. This cancause component damage.

A. Use the installation tool to push down on theToric Ring and face seal.

B. With your fingers, pull up uniformly on the ToricRing and face seal.

CAUTIONApply isopropyl alcohol to the Toric Ring. Checkthe retaining lip of the seal seating area for burrsor fins, which can cause a seal to leak. Damage tocomponents can result.

3. Apply isopropyl alcohol as a lubricant to the ToricRing and place in the seating area. If installationdoes not appear smooth, flat and correct, removethe seal from the spindle and repeat the process.

CAUTIONTo prevent slippage of the Toric Ring, allowsufficient evaporation time for the assemblylubricant before proceeding with furtherassembly. Damage to components can result.

4. [Figure 5.29] Seat Toric Ring correctly. Oncecorrectly in place, the Toric Ring must roll on ramponly.

!

!

!

Figure 5.29

Figure 5.28

Figure 5.27

- 52 -

Section 5Assembly

Wheel Hub to Spindle Assembly

NOTE: Complete the assembly of the wheel hub tothe spindle. Before installing the wheel hub onto thespindle, however, keep the following points in mindto ensure correct sealing between the faces of theToric Ring:

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

CAUTIONBring the housings together slowly. High impactcan result in component damage. Removeprotective pad from the spindle's seal journal.

2. Remove the protective pad from the spindle's sealjournal.

CAUTIONDo not apply lubricant to the Toric Ring. TheToric Ring can leak. Damage to components can result.

3. Apply a light coating of Dow Corning GNmolybdenum assembly paste lubricant to the twomating surfaces of the face seal’s steel rings only.Do not allow this lubricant to contact the ToricRing. The Toric Ring can leak. Figure 4.30.

• When installing the hub onto the spindle, both sealhousings must be aligned correctly.

• [Figure 5.30] Slowly bring the hub and spindleassembly together as the spindle bearingadjustment nut is tightened.

!

!

• If the seals are not aligned correctly: Theseals will move. Any wobbling motion of theseals is an indication of incorrectly positioned(cocked) seals. Dirt can enter past the ToricRing.

• [Figure 5.31] The Toric Rings have slipped,instead of rolling on the left-hand side of theseal. Note how the top Toric Ring is to the rightand the bottom Toric Ring is to the left. Thesame seals are also shown after the bottomhalf is rotated 90 degrees.

• If the Toric Ring slips at any location, it willtwist, causing the formed seal rings to seatincorrectly (cock).





2. Rotate the hub in both directions. At the sametime, tap the hub several times with a brass orplastic mallet.

3. Tighten the nut using the spindle nut tool0979534000. Tighten further until one of thenut’s scallops lines-up with one of the threadedholes in the ring hub. See special tool section.See "Torque Table" in section 6.

!

Figure 5.31

Figure 5.30

FACE SEALMATINGSURFACES

- 53 -

Section 5Assembly





8. Apply a thin layer of axle grease to the face of thesun gear thrust washer.






• Insure washer tangs are keyed into the spindle nutslots.






!





D. Insert the planet gear on the planet shaft suchas the rollers end up between the planet shaftOD and planet gear ID with the grooved face ofthe planet gear down against the shaft flange.




5. Install the thrust washer.

6. Install the corresponding O-rings into each planetgears subassembly.




Figure 5.32

- 54 -

Section 5Assembly

Final Assembly









Fill Wet Disc Brakes with Hydraulic Fluid

1. Fill the wet disc brakes with tractor oil universal(TOU) fluid by using the 0.875"-14 UNFO-ring plug near the top of the brake and a0.875"-14 UNF O-ring plug above the three ornine o’clock position. Fill the brakes until oil exitsthe lower plug (above the 3 or 9 o’clock position).

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

NOTE: Brake coolant inlet is connected to the0.875"-14 UNF O-ring plug at the top position of thebrake between the mounting bolts. The brakeactuation line is connected at the 0.5625"-18 UNFplug at either the three or nine o’clock position.

3. Thoroughly bleed all air from brake actuationsystem.

4. Preform pressure test on brake apply circuit.

- 55 -

Section 6Specifications

PRC 485 Q Plus™ Wheel End Torque Chart

Item Fastener Torque Value

1 Wheel rim nut Per OEM specification

2 Oil fill/level/drain plug 35 lb-ft (47 N•m)

3 Spindle and brake spider mounting (drum) 200-260 lb-ft (270-350 N•m)

4 Camshaft bracket clamp 35-50 lb-ft (47-68 N•m)

5 Camshaft bracket to spider 90-120 lb-ft (122-163 N•m) - not shown

6 Wheel bearing adjusting nut 400 lb-ft (542 N•m)

7 Adjusting nut set screw 35 lb-ft (47 N•m)

8 Dust shield mounting 3/8”-16 grade 8 30-50 lb-ft (41-68 N•m) - not shown

9 Air chamber mounting 133-155 lb-ft (180-210 N•m) - not shown

10 Push rod locknut 5/8”-18 25-50 lb-ft (34-68 N•m) - not shown

11 Planetary spider-to-wheel hub slotted head screw Refer to instructions in Section 3

1

7

2

113

4

65

9

10

8

PRC 485 W3H Wheel End Torque Chart



2 Spindle and wet disc brake housing mounting 370-480 lb-ft (500-650 N•m) - not shown



5 Brake housing capscrews 200-258 lb-ft (270-350 N•m)

6 Piston return spring shoulder bolts 22-30 lb-ft (30-40 N•m)

7 Oil fill/drain plug (not shown) 35 lb-ft (47 N•m)

8 Planetary spider-to-wheel hub slotted head screw Hand tighten (No spcification)

1

3

2

5

4

6

7

8

- 56 -


- 57 -


PRC 785P Wheel End Torque Chart





4 Camshaft bracket to spider 90-120 lb-ft (122-163 N•m)

5 Camshaft bracket clamp 35-50 lb-ft (47-68 N•m)

6 Spindle and brake mounting (drum) 370-480 lb-ft (500-650 N•m)

7 Oil fill/drain plug 35 lb-ft (47 N•m) -

8 Dust shield mounting 3/8”-16 grade 8 30-50 lb-ft (41-68 N•m) - not shown

9 Air chamber mounting 133-155 lb-ft (180-210 N•m) - not shown

10 Push rod locknut 5/8”-18 25-50 lb-ft (34-68 N•m) - not shown

11 Planetary spider-to-wheel hub slotted head screw Hand tighten (No spcification)

10

9

6

1

3

2 7

34

8

5

PRC 785 W3H Wheel End Torque Chart





4 Spindle and wet disc brake mounting 370-480 lb-ft (500-650 N•m)

5 Brake housing capscrews 200-258 lb-ft (270-350 N•m)

6 Oil fill/drain plug 35 lb-ft (47 N•m)

7 Piston return spring shoulder bolts 22-30 lb-ft (30-40 N•m)

4

1

2

6

6

5

7

3

- 58 -


- 59 -


Lubrication Specification

NOTE: Do not fill only through the axle housingbowl. For axles with a common level, fill the axle ateach wheel end and the axle housing bowl to thebottom of the fill/level plug hole with the specified oil.Wait and allow the oil to flow through the axle. Checkthe oil level again and fill to the specified level ifnecessary.

Lubrication Schedule

Operation Off-HighwayÀ

Initial Oil Change 250 operating hoursÀ

Check Oil Level 250 operating hoursÀ

Petroleum Oil 1,500 operating hours or twice a yearChange (whichever comes first)À

Synthetic Oil or 3,000 operating hours or once a yearSemi-Synthetic Oil (whichever comes first)Change

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

Lubrication Specifications

Outside TemperatureSAE

AxleTech Specification Oil°F °C

Specifications Approval Description Min. Max. Min. Max.

O-76A, Gear Oil GL-5, SAE 85W/140 10 None -12 None

O-76D, Gear Oil SAE J 2360 GL-5, SAE 80W/90 -15 None -26 None

O-76E, Gear Oil GL-5, SAE 75W/90 -40 None -40 None

O-76L, Gear Oil GL-5, SAE 75W/140 -40 None -40 None

O-76M, Gear Oil GL-5, SAE 75W/140 -40 None -40 None

O-76N, Gear Oil GL-5, SAE 75W/140 -40 None -40 None

Specification Oil Description

Tractor oil SAE 10W, 20W or 10W30universal (TOU)

Wet Disc Brake Coolant Specifications

Sump and Forced Cooling Systems with Hub Seals

Coolant Specification

Petroleum Base See the recommendations of the vehicle manufacturer.SAE 10W, SAE 20W or SAE 10W30

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

CAUTIONThe operating temperature of the coolant mustnever reach or exceed 250°F (120°C). If theoperating temperature of the coolant reaches orexceeds 250°F (120°C), the internal componentsof the brake will be damaged. A forced coolingsystem may be required to assure the coolanttemperature remains below 250°F (120°C).

!

Coolant Change IntervalsBreak-In Interval: Change the fluid in the brake housing after the first month or the first 200-250 hours of operation,

whichever comes first.

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

Hydraulic Fluid SpecificationsUse only the brake hydraulic fluid specified by the manufacturer of the vehicle. Do not use different hydraulic fluids. The wrong fluid willdamage the seals on the piston.

- 60 -


- 61 -

Section 7Special Tools & Procedures

Spindle Nut Tool

Planetary Spider Assembly Tool

Toric Ring Face Seal Assembly Tool

Figure 7.1

Figure 7.2

Figure 7.3

TOOL 860901002TTRS TORIC RING FACESEAL INSTALLATION

TOOL 0979534000

TOOL 0979539000 FOR PRC 785TOOL 0979600000 FOR PRC 485

Suite 400 AxleTech International France AxleTech do Brasil Sistemas Automotivos Ltda.3001 West Big Beaver Road 4, Rue Jean Servanton Avendia Joao Batista, 830Troy, Michigan 48084 Boite Postale 656 Centro-Osasco-SPU.S.A. 42042 Saint Etienne Cédex 1 06097095 BrasilToll Free: 877-877-9717 France Phone: +55 11 36846641Non-Toll Free: 248-816-5401 (33) 477.92.88.00 Fax: +55 11 36846859Fax: 248-435-1990 Fax: (33) 477.92.88.93Website: www.axletech.com

MM9N © Copyright AxleTech InternationalIssued 03-07 Printed in the USA

planetary axle wheel ends - axletech axle wheel ends extrémité de roue à réduction planétaire...

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