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TM 9-2320-361-24-1 0140 00

0140 00-4

INTERMEDIATE PROPELLER SHAFT MAINTENANCE (M36A2) (Contd)

CLEANING AND INSPECTION WARNING

Skysol 100 solvent is combustible; DO NOT use or store nearheat, sparks, flame, or other ignition sources. Use mechanical ventilation whenever product is used in a confined space,heated above ambient temperatures, or agitated. Keepcontainer sealed when not in use.Contact with Skysol 100 may cause skin irritation. Usechemical-resistant gloves. In case of skin contact, remove anycontaminated clothing and wash skin thoroughly with soap andwater. Wash contaminated clothing before reuse. Eye contactmay cause irritation, tearing, or blurring of vision. Use faceshield or goggles when eye contact may occur. In case of eyecontact, flush eyes with large amounts of water for at least 15minutes or until irritation subsides. Inhalation may causeirritation to upper respiratory passages. DO NOT have food ordrink in the vicinity. Failure to comply may result in injury topersonnel.

1. Clean all parts with Skysol 100 and dry with clean rag.2. Clean and inspect bearing (19) in accordance with TM 9-214.3. Inspect universal joint (24) for roughness and free play. Replace universal joint (24) if loose or

rough (WP 0141 00) .4. Inspect propeller shaft (23) for:

a. Breaks, cracks, or bends. Replace if cracked, bent, or broken.b. Crossed or stripped threads. Replace if threads are crossed or stripped.c. Nicked or burred splines (28). Replace if splines are cracked or chipped.d. Bearing shoulder nicked, burred, or scored. Replace if bearing shoulder is nicked, burred,

scored, or bearing (19) is frozen.5. Inspect shield (20) for cracks, breaks, or bends. Replace shield (20) if cracked, broken, or bent.6. Inspect flange (11) for cracks, breaks, and bent deflector (12). Replace flange (11) if damaged.7. Inspect rubber insulators (14) for tears or breaks. Replace rubber insulators (14) if torn or broken.8. Inspect bearing housing (17) for cracks and breaks. Replace bearing housing (17) if cracked or

broken.9. Inspect frame support (4) for breaks and cracks. Replace frame support (4) if broken or cracked.

ASSEMBLY

1. Apply a light film of GAA grease to bearing (19) outer race and inner bore of bearing housing (17).Install bearing (19) in bearing housing (17). Ensure bearing (19) is seated square in bearing housing (17).

2. Install two new seals (13) in shaft side of bearing housing (17).3. Slide shield (20) on shaft (23) as far as it will go.4. Install shield (20) with screw (22) and new lockwasher (21) on shaft (23).5. Install four rubber insulators (14) in bearing housing (17).

NOTE

Perform step 6 if lubrication fitting was removed.

6. Install lubrication fitting (18) in bearing housing (17).

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TM 9-2320-361-24-1 0140 00

0140 00-5/6 blank

INTERMEDIATE PROPELLER SHAFT MAINTENANCE (M36A2) (Contd)

INSTALLATION1. Install frame support (4) to crossmember (6) with four screws (5) and new locknuts (3).

2. Install flange yoke (25) on studs (1) of transfer flange (27) in parking brake drum (2) with fournew locknuts (26). Ensure scribed marks align. Tighten locknuts (26) 90120 lb-ft (122163 N m).

3. Install bearing housing (17) to frame support (4) with two screws (7), washers (15), and newlocknuts (16).

4. Install deflector (12) and flange (11) on shaft (23) with washer (10) and nut (9).

5. Tighten nut (9) on shaft (23) 260290 lb-ft (353393 N m).

6. Install new cotter pin (8) through nut (9).

7. Ensure shaft (23) turns freely and with no side play at U-joint (24) and support bearing (19).

8. Install forward-rear propeller shaft (WP 0139 00) .

9. Lubricate bearing housin g (WP 0020 00) .

10. Connect battery ground cable (WP 0126 00) .11. Release parking brake and remove wheel chocks (TM 9-2320-361-10).

END OF WORK PACKAGE

6

5

7

4

3

8

910

11

14

14

15

16

19

1820

21

2223

26

25

2

1

27

13

13 12

17

24

28

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TM 9-2320-361-24-1 0141 00

0141 00-1

FIELD MAINTENANCE INSTRUCTIONS

2-1/2 TON, 6X6, M44A2 SERIES TRUCKS (MULTIFUEL)

UNIVERSAL JOINT MAINTENANCEDISASSEMBLY, CLEANING AND INSPECTION, AND ASSEMBLY

INITIAL SETUP:

Applicable Models All

Materials/PartsFour retaining rings (item 311, WP 0470 00)GAA grease (item 17, WP 0468 00)Rags (item 27, WP 0468 00)Skysol 100 (item 13, WP 0468 00)

ReferencesTM 9-2320-209-12TM 9-214

Equipment ConditionPropeller shaft removed (WP 0139 00) .Intermediate propeller shaft removed (M36A2)

(WP 0140 00) .

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TM 9-2320-361-24-1 0141 00

0141 00-2

UNIVERSAL JOINT MAINTENANCE (Contd)

NOTE

Do not remove bearings from caps, except when replacing caps.

Mark mating yoke position for installation.

REMOVAL 1. C-ring and retaining ring type:

a. Remove four retaining rings (1) from yoke (5) and yoke flange (3). Discard retaining rings (1).

b. Remove four bearing caps (2), yoke flange (3), and universal joint (4) from yoke (5).

c. Remove four seals (6) and lubrication fitting (7) from universal joint (4). Discard seals (6).

2. Cap type:

a. Remove eight screws (8), four straps (9), and bearing caps (10) from yoke (5) and yokeflange (3).

b. Remove yoke flange (3) and universal joint (4) from yoke (5).

c. Remove four seals (6) and lubrication fitting (7) from universal joint (4). Discard seals (6).

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3

21

5 21

4

9108

5 109

8

7

3

4

CAP TYPE

C-RING AND RETAINING RING TYPE 6

7

4

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Skysol 100 solvent is combustible; DO NOT use or store nearheat, sparks, flame, or other ignition sources. Use mechanical

ventilation whenever product is used in a confined space,heated above ambient temperatures, or agitated. Keepcontainer sealed when not in use.

Contact with Skysol 100 may cause skin irritation. Usechemical-resistant gloves. In case of skin contact, remove anycontaminated clothing and wash skin thoroughly with soap andwater. Wash contaminated clothing before reuse. Eye contactmay cause irritation, tearing, or blurring of vision. Use faceshield or goggles when eye contact may occur. In case of eyecontact, flush eyes with large amounts of water for at least 15

minutes or until irritation subsides. Inhalation may causeirritation to upper respiratory passages. DO NOT have food ordrink in the vicinity. Failure to comply may result in injury topersonnel.

1. Clean all parts with Skysol 100 and dry with clean rag.

2. Inspect yokes (2) for breaks, cracks, and bends. Replace yokes (2) if damaged.

3. Inspect retaining ring grooves (1) for damage. Replace yoke flange (7) or yoke (2) if retaining ring grooves (1) are damaged.

4. Inspect shaft (3) for bends, cracks, and damaged threads (5) or splines (4). Replace shaft (3) if damaged, bent or cracked.

5. Inspect bearings (6) in bearing cap (2) (TM 9-214). Replace U-joint if damaged.

1

1

21

6

3 4 5

7

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ASSEMBLY 1. C-ring and retaining ring type:

a. Apply thick film of GAA grease to bearing caps (8) to hold bearings (6) in place during assembly.b. Install four new rubber seals (11) on universal joint journals (12).c. Install universal joint journals (12) in yoke flange (7). Press two bearing caps (8) into yoke

flange loops (10).d. Ensure retaining ring groove (1) in outside edge of both yoke loops (10) are visible. Install two

new retaining rings (14).NOTE

Align marks on yokes before assembling bearing caps in shaftyoke.

f. Position yoke (2) on universal joint journals (12), and install two bearing caps (8) and newretaining rings (14).

g. Install lubrication fitting (13) on universal joint (9).

8

6

910

7

11

1213

9

14

6

1

10

79

8

14

8

7

12

14

82

9

C-RING AND RETAINING RING

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NOTE


2. Cap type:

a. Install four new seals (8) on universal joint journals (9).

b. Install lubrication fitting (10) on universal joint (7).

c. Install universal joint (7) in upper yoke flange loop (5) with lubrication fitting (10) angled awayfrom yoke flange (6).

d. Apply GAA grease in bearing caps (3) to hold bearing (4) in place during assembly.

e. Install two bearing caps (3) on universal joint journal (9) and upper yoke flange loop (5).

f. Position two locking straps (2) on bearing caps (3) and install with four screws (1). Tightenscrews (1) 1825 lb-ft (2434 N m). Bend tabs of locking straps (2) up to hold screws (1) in place.

NOTE


Shaft yoke and yoke flange should move smoothly and haveno free play.

g. Position shaft yoke (11) on universal joint journals (9) and install two bearing caps (3) withnew locking straps (2) and four screws (1). Tighten screws (1) 1825 lb-ft (2434 N m).

h. Bend tabs of locking straps (2) up to hold screws (1) in place.

3. Install propeller shaft (WP 0139 00) .

4. Install intermediate propeller shaft (M36A2) (WP 0140 00) .

END OF WORK PACKAGE

8

910

7

CAP TYPE

1

2

3

4

5

6

7

1 23

6

9

12

311

10

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FRONT AXLE SHAFT AND UNIVERSAL JOINT MAINTENANCEREMOVAL, CLEANING AND INSPECTION, AND INSTALLATION

INITIAL SETUP:


Materials/PartsTwelve lockwashers (item 233, WP 0470 00)Washer (item 373, WP 0470 00)Washer (item 376, WP 0470 00)GO 80/90 (item 25, WP 0468 00)Skysol 100 (item 13, WP 0468 00)Rags (item 27, WP 0468 00)Sealing compound (item 32, WP 0468 00)Cap and plug set (item 10, WP 0468 00)

ReferencesWP 0020 00WP 0141 00WP 0172 00

Equipment ConditionParking brake set and wheels chocked

(TM 9-2320-361-10).Battery ground cable disconnected

(WP 0126 00) .Front hubs and drums removed (WP 0187 00) .

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FRONT AXLE SHAFT AND UNIVERSAL JOINT MAINTENANCE (Contd)

REMOVAL WARNING

Accidental or intentional introduction of liquid contaminantsinto the environment is a violation of state, federal, andmilitary regulations. Refer to Army POL (WP 0001 00 ) forinformation concerning storage, use, and disposal of theseliquids. Failure to do so may result in damage to environmentand health of personnel.

CAUTION

Plug all openings after disconnection to prevent contamination.NOTE

Left and right side front axle shafts are replaced the sameway. This procedure covers the right side front axle shaft.

Use a drain pan to capture any draining oil. Dispose of fluids

in accordance with local policy and ordinances. Ensure allspills are cleaned up.

1. Remove screw (2), two washers (3), and hose connector (4) from wheel cylinder (1). Discardwashers (3).

2. Remove spring (6) from brakeshoes (7).

3. Remove twelve nuts (10), lockwashers (9), and deflector (5) from brake plate (8). Discardlockwashers (9).

4. Remove brake plate (8) from spindle (11).

5. Slide spindle (11) and thin thrust washer (12) off outer shaft of front axle shaft (16).

6. Carefully pull front axle shaft (16) out of axle housing (15) and steering knuckle (14).

7. Remove thick thrust washer (13) from front axle shaft (16).

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1

2

34

3

5

910

8

7

16

15

14

13

16

1211

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CLEANING AND INSPECTION1. Inspect for worn U-joint as follows:

a. Place short shaft (3) in vise and twist shaft (1) back and forth checking for free play.b. Push and pull shaft (1) and check for free play.

c. Check universal joint (2) for roughness, binding, or free play. Replace universal joint (2) if damaged (WP 0141 00) .

WARNING



Contact with Skysol 100 may cause skin irritation. Use

chemical-resistant gloves. In case of skin contact, remove anycontaminated clothing and wash skin thoroughly with soap andwater. Wash contaminated clothing before reuse. Eye contactmay cause irritation, tearing, or blurring of vision. Use faceshield or goggles when eye contact may occur. In case of eyecontact, flush eyes with large amounts of water for at least 15minutes or until irritation subsides. Inhalation may causeirritation to upper respiratory passages. DO NOT have food ordrink in the vicinity. Failure to comply may result in injury topersonnel.

2. Clean all metal parts with rag saturated with Skysol 100. Do not clean brake lining or any partsof wheel cylinder with Skysol 100. Clean sealer remains from mating surfaces.

3. Inspect shafts (1) and (3), including yokes (14), for breaks, cracks, or bends. Replace shafts (1) or(3) if damaged.

4. Inspect splines (12) and (16) for nicks, burrs, or chipping. Replace shafts (13) or (15) if nicked,burred, or chipped.

5. Inspect thrust washers (4) and (5) for evidence of overheating (discoloration) or scoring. Replacethrust washers (4) and (5) if discolored or scored.

6. Inspect spindle (8), bearing sleeve (6), and bearing surfaces (7) and (9) for scoring. Replacespindle (8) if scored.

7. Inspect studs (10) of steering knuckle (11) for stripped or crossed threads. Replace studs (10) if threads are stripped or crossed.

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2

1

3

VISE VISE

4 5

67 8 9

12 13 15

14

16

11

10

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18

19

2021

21

16 15 1417

13

12

11

9

8

76

543

10

21

END OF WORK PACKAGE

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FRONT AND REAR AXLE BREATHER MAINTENANCEREMOVAL, CLEANING, AND INSTALLATION

INITIAL SETUP:


Materials/PartsRags (item 27, WP 0468 00)Skysol 100 (item 13, WP 0468 00)



(WP 0126 00) .

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FRONT AND REAR AXLE BREATHER MAINTENANCE (Contd)

REMOVAL NOTE

This procedure is for all axles.Remove breather (1) from axle housing (2).

CLEANING WARNING





Clean breather (1) in Skysol 100 and dry with clean rag.

INSTALLATION1. Install breather (1) in axle housing (2).

2. Connect battery ground cable (WP 0126 00) .

3. Release parking brake and remove wheel chocks (TM 9-2320-361-10).

1

2

END OF WORK PACKAGE

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STEERING KNUCKLE BOOT REPLACEMENTREMOVAL AND INSTALLATION

INITIAL SETUP:


Materials/PartsFour lockwashers (item 239, WP 0470 00)Steering knuckle, dust boot parts kit

(item 293, WP 0470 00) Adhesive (item 1, WP 0468 00)



(WP 0126 00) .

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STEERING KNUCKLE BOOT REPLACEMENT (Contd)

REMOVAL NOTE

Left and right steering knuckle boots are replaced the sameway. This procedure covers the left side.

1. Remove four screws (1), lockwashers (2), and boot guard (3) from steering arm (5) and knuckle (4).Discard lockwashers (2).

2. Hold nut (8) and loosen screw (6) and washer (7) on outer clamp (9).3. Remove outer clamp (9) and slide boot (11) off toward center of vehicle.4. Pull boot (11) off steering knuckle (4).5. Hold nut (14), loosen screw (12) and washer (13), and slide inner clamp (15) off boot (11) toward

center of vehicle.6. Pull boot (11) away from axle housing (18).

NOTE

Cut boot only if necessary for removal. Replacement boots are

equipped with zippers.7. Cut boot (11) from edge (15) to edge (17). Remove and discard boot (11).

INSTALLATIONNOTE

When boot is properly installed, zipper will be toward front onleft side and toward rear on right side

1. Place new boot (11) around axle housing (18) so that when zipped up, zipper tab (10) is outside of boot (11).

2. Close zipper (10) all the way.3. Thoroughly coat zipper (10) with adhesive sealer.

NOTE

Ensure word TOP is facing upward when installing boot.4. Place small end of boot (11) over groove in axle housing (18). Slide small clamp (16) over boot (11)

until fully seated in groove of axle housing (18). Screw (12), washer (13), nut (14), and clamp (16)must be positioned on top of axle housing (18), and clamp (16) must be between two beads of boot (11).

5. While holding nut (14), tighten screw (12) and washer (13) of clamp (16). Check that clamp (16) isholding boot (11) in groove of axle housing (18).

6. Fold free inner edge of boot (11) over itself and place over groove in steering knuckle (4). Tab (10)of zipper is now inside of boot (11).

NOTE

When steering knuckle boot clamp is installed, ensure screwand nut are located toward front and at top of steering knucklewhen tightened.

7. Slide larger clamp (9) over boot (11) and seat clamp (9) in groove of steering knuckle (4). Ensureclamp (9) is seated all the way around steering knuckle (4) and is between two beads of boot (11).

8. While holding nut (8), tighten screw (6) and washer (7) of clamp (9).9. Using adhesive sealer, seal around both edges of boot (11) to steering knuckle (4) and axle housing

tube (18).10. Install boot guard (3) on steering arm (5) and steering knuckle (4) with four new lockwashers (2)

and screws (1).11. Connect battery ground cable (WP 0126 00) .


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STEERING KNUCKLE BOOT REPLACEMENT (Contd)

1

5

2

3

42

1

6

7

8

9

10

411 ~

4 12 13

14

15

16

18

17

END OF WORK PACKAGE

10 12

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FRONT AXLE SHAFT FLANGE MAINTENANCEREMOVAL, CLEANING AND INSPECTION, AND INSTALLATION

INITIAL SETUP:


Materials/PartsGasket (item 67, WP 0470 00)Eight lockwashers (item 206, WP 0468 00)GAA grease (item 17, WP 0468 00)Rags (item 27, WP 0468 00)Skysol 100 (item 13, WP 0468 00)

ReferencesWP 0142 00



(WP 0126 00) .

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FRONT AXLE SHAFT FLANGE MAINTENANCE (Contd)

REMOVAL 1. Remove eight screws (1) and lockwashers (2) from axle flange (3) and hub (5). Discard

lockwashers (2).2. Loosen axle flange (3) from axle shaft (6).

3. Remove axle flange (3) and gasket (4). Discard gasket (4).

CLEANING AND INSPECTION1. Clean gasket (4) remains from mating surfaces.

WARNING


ventilation whenever product is used in a confined space,heated above ambient temperatures, or agitated. Keepcontainer sealed when not in use.Contact with Skysol 100 may cause skin irritation. Usechemical-resistant gloves. In case of skin contact, remove anycontaminated clothing and wash skin thoroughly with soap andwater. Wash contaminated clothing before reuse. Eye contactmay cause irritation, tearing, or blurring of vision. Use faceshield or goggles when eye contact may occur. In case of eyecontact, flush eyes with large amounts of water for at least 15minutes or until irritation subsides. Inhalation may causeirritation to upper respiratory passages. DO NOT have food ordrink in the vicinity. Failure to comply may result in injury topersonnel.

2. Clean axle flange (3) in Skysol 100 and dry with clean rag.3. Clean gasket (4) surface on hub (5) with rag saturated with Skysol 100, and dry with clean rag.

4. Inspect axle flange (3) for:

a. Cracks and breaks. Replace if cracked or broken.

b. Nicked, burred, or cracked female splines. Remove minor nicks or burrs with fine-mill file oremery cloth. Replace splines if cracked.

c. Inspect plug (7) for tightness. Replace if loose or leaking lubricant.

5. Inspect male splines on axle shaft (6) for nicks, burrs, or cracks. Remove minor nicks or burrs withfine-mill file or emery cloth. Replace axle shaft if splines are cracked (WP 0142 00) .

INSTALLATION1. Coat one side of new gasket (4) with GAA grease and align over holes in hub (5).

2. Align holes in axle flange (3), gasket (4), and hub (5), and install with eight new lockwashers (2)and screw (1). Tighten 6080 lb-ft (81108 N m).



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FRONT AXLE SHAFT FLANGE MAINTENANCE (Contd)

END OF WORK PACKAGE

1 2

3 4

7

6

5

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REAR AXLE SHAFT MAINTENANCEREMOVAL, CLEANING AND INSPECTION, AND INSTALLATION

INITIAL SETUP:


Materials/PartsGasket (item 67, WP 0470 00)Eight lockwashers (item 206, WP 0468 00)GAA grease (item 17, WP 0468 00)

Materials/Parts (Contd)Rags (item 27, WP 0468 00)Skysol 100 (item 13, WP 0468 00)



(WP 0126 00) .

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REAR AXLE SHAFT MAINTENANCE (Contd)

REMOVAL 1. Remove eight screws (1) and lockwashers (2) from flange (3) and hub (6). Discard lockwashers (2).

2. Remove flange (3) and axle shaft (4) as an assembly, and gasket (5) from hub (6) and axle housing (7). Discard gasket (5).






1. Clean gasket (5) residue from mating surfaces.

2. Clean axle shaft (4) with rag saturated in Skysol 100. Dry with clean rag,

3. Inspect axle shaft (4) for cracks, breaks, and bends. Replace axle shaft (4) if cracked, broken, orbent.

4. Inspect axle shaft (4) splines for nicks, burrs, cracks, and breaks. Remove minor nicks and burrswith a fine-mill file or emery cloth. Replace if splines are cracked or broken.

INSTALLATION

1. Coat one side of new gasket (5) with GAA grease and align over holes in hub (6).

2. Carefully insert axle shaft (4) into hub (6) and axle housing (7). Turn axle shaft (4) until splines of axle shaft (4) seat in differential. Align holes of flange (3) to holes in gasket (5) and hub (6).

3. Install flange (3) with eight new lockwashers (2) and screws (1). Tighten screws (1) 81104 lb-ft(110189 N m).



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REAR AXLE SHAFT MAINTENANCE (Contd)

7

6

5

43

21

END OF WORK PACKAGE

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FRONT AXLE REPLACEMENTREMOVAL AND INSTALLATION

INITIAL SETUP:


Tools and Special ToolsGeneral mechanics tool kit

(item 116, WP 0469 00)Torque wrench, 3/4-in. drive

(item 137, WP 0469 00)Hydraulic jack (item 47, WP 0469 00)Jack stands

Materials/PartsEight lockwashers (item 238, WP 0470 00)Lubricating oil, GO 80/90

(item 25, WP 0468 00)

Personnel RequiredTwo

ReferencesWP 0020 00



(WP 0126 00) .Front wheels removed (WP 0186 00) .Front propeller shaft removed (WP 0139 00) .Drag link removed (WP 0195 00).Brake line removed at tee fitting on front axle

(WP 0175 00) .Front shock absorbers removed (WP 0160 00) .

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FRONT AXLE REPLACEMENT (Contd)

WARNING

Weight of vehicle must be supported on jack stands at all times.

Do not attempt to support weight of vehicle on hydraulic jack.Failure to comply may result in injury or death to personnel.

REMOVAL 1. Raise axle (4) with hydraulic jack under differential (3) and place two jack stands under left and

right springs (10) between axle (4) and spring (10) hangers.

2. Remove eight nuts (6), lockwashers (7), and two clamp plates (8) from axle (4). Discardlockwashers (7).

3. Remove four U-bolts (1) and two saddle plates (2). WARNING

Axle is heavy. Ensure axle is balanced and personnel are clear

before lowering axle. Failure to comply may result in injury topersonnel.NOTE

Two assistants will help with step 4.

4. Lower axle (4) until it clears vehicle. Remove axle (4) from under vehicle and place on jack stands.

INSTALLATION WARNING

Axle is heavy. Ensure axle is balanced and personnel are clearbefore raising axle. Failure to comply may result in injury topersonnel.

NOTE

Two assistants will help with installation.

1. Remove axle (4) from jack stands and place under vehicle.

2. Position spring seats (5) on axle (4) under springs (10).

3. Raise axle (4) until holes in spring seats (5) meet spring centering bolts (9).

4. Install four U-bolts (1) on two saddle plates (2).NOTE

Install clamp plates with shock absorber mounting holes onoutside, toward rear of vehicle, and angled down.

5. Install two clamp plates (8) on four U-bolts (1) with eight new lockwashers (7) and nuts (6).Tighten nuts (6) 190230 lb-ft (258312 N m).

6. Install front shock absorbers (WP 0160 00) .

7. Install brake line at tee fitting on front axle (WP 0175 00) .

8. Install drag link (WP 0195 00).

9. Install front propeller shaft (WP 0139 00 ).

10. Install front wheels (WP 0186 00) .


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FRONT AXLE REPLACEMENT (Contd)

END OF WORK PACKAGE

HYDRAULIC JACK

JACK STANDS

~

1

10

1

2

3

4

59

87

6

INSTALLATION (Contd)12. Fill axle housing with GO 80/90 (WP 0018 00) .


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0149 00-1



FRONT AND REAR DIFFERENTIAL OIL SEAL REPLACEMENTREMOVAL AND INSTALLATION

INITIAL SETUP:




(item 137, WP 0469 00)Mechanical puller kit (item 64, WP 0469 00)Oil seal replacer (item 80, WP 0469 00)

Materials/PartsCotter pin (item 26, WP 0470 00)Oil seal (item 356, WP 0470 00)



(WP 0126 00) .Propeller shaft removed (WP 0139 00) .

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FRONT AND REAR DIFFERENTIAL OIL SEAL REPLACEMENT (Contd)

REMOVAL 1. Remove cotter pin (12), nut (1), and washer (2) from shaft (8). Discard cotter pin (12).

2. Remove flange (3) from shaft (8).NOTE

Perform step 3 if replacing dirt deflectors.

3. Remove dirt deflector (4) from flange (3).

4. Remove six screws (11) and washers (10) from retainer (6).NOTE

Count and record number of shims for installation.

5. Remove retainer (6) and shims (7) from carrier (9).

6. Remove oil seal (5) from retainer (6). Discard oil seal (5).

INSTALLATION1. Install new oil seal (5) in retainer (6).

2. Install shims (7) and retainer (6) on carrier (9) with six washers (10) and screws (11). Tightenscrews (11) 6585 lb-ft (88115 N m).

NOTE

Perform step 3 if replacing dirt deflectors.

3. Install dirt deflector (4) on flange (3) and install flange (3) on shaft (8).

4. Install washer (2) and nut (1) on shaft (8). Tighten nut (1) 300600 lb-ft (407814 N m).

5. Install new cotter pin (12) on nut (1) and shaft (8).

6. Install propeller shaft (WP 0139 00) .


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FRONT AND REAR DIFFERENTIAL OIL SEAL REPLACEMENT (Contd)

END OF WORK PACKAGE

1 23

45

6

1011

12 89

7

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STEERING KNUCKLE AND STEERING ARM MAINTENANCESTEERING ARM REMOVAL, STEERING KNUCKLE REMOVAL, CLEANING AND INSPECTION, STE

INSTALLATION, STEERING ARM INSTALLATION, END PLAY TEST, AND TURN ANGLE SCREW

INITIAL SETUP: Applicable Models

All



(item 137, WP 0469 00)Inside micrometer (item 49, WP 0469 00)Outside micrometer (item 50, WP 0469 00)Dial indicator (item 43, WP 0469 00)Mechanical puller kit (item 64, WP 0469 00)1-5/16-in. socket, 3/4-in. drive

(item 101, WP 0469 00)Wheel alignment indicator

(item 44, WP 0469 00)

Jack stands

Materials/PartsEight lockwashers (item 239, WP 0470 00)Twelve lockwashers (item 202, WP 0470 00)Four bushings (item 417, WP 0470 00)

Lubricating oil, GO 80/90(item 25, WP 0468 00)

ReferencesTC 9-237WP 0021 00



(WP 0126 00) .Front axle shaft removed (WP 0142 00) .Steering knuckle boot removed (WP 0145 00) .Tie rod removed (WP 0194 00).Drag link removed (WP 0195 00).

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STEERING KNUCKLE AND STEERING ARM MAINTENANCE(Contd)

STEERING ARM REMOVAL 1. Remove lubrication fitting (4) from steering arm (5).

2. Remove four nuts (2) and lockwashers (3) from steering arm (5). Discard lockwashers (3).3. Tap steering arm (5) at point A to loosen four bushings (1).

4. Remove four bushings (1) and steering arm (5) from steering knuckle (8). Discard four bushings (1).

5. Remove four bushings (1) from steering arm (5).

STEERING KNUCKLE REMOVAL NOTE

Perform step 1 for left steering knuckle. Perform step 2 for rightsteering knuckle.

1. Remove lubrication fitting (11) from steering knuckle (8).

2. Remove lubrication fitting (19), four screws (18), lockwashers (17), and plate (20) from steering knuckle (8). Discard lockwashers (17).

3. Remove spacer (6), bearing (7), and sleeve (16) from left and right steering knuckles (8).

4. Remove four screws (10), lockwashers (9), plate (12), sleeve (14), and bearing (13) from left andright steering knuckles (8). Discard lockwashers (9).

5. Remove left and right steering knuckles (8) from two pins (15).

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RIGHT SIDE

LEFT SIDE

1918

20

6

7

17

16

1

2

43

5

616

15

7

8

10

11

12

13

14

15

9

RIGHT SIDE8

POINT A

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CLEANING AND INSPECTION1. For general cleaning instructions, refer t o WP 0021 00.

2. Measure outside diameter of ball stud (21). Replace ball stud (21) if outside diameter is less than1.24 in. (3.15 cm).

3. Visually inspect ball stud (21) for nicks, scratches, pits, scores, or scratches. Replace ball stud (21)if damaged.

4. Measure outside diameter of steering knuckle pins (18). Replace front axle if outside diameter of steering knuckle pin is less than 1.123 in. (2.852 cm).

5. Inspect steering knuckle pins (18) for nicks, scratches, pitting, scores, and cracks. Replace frontaxle if pins (18) are nicked, scratched, pitted, scored, or cracked.

6. Inspect sleeves (17) and (20) for nicks, scratches, scores, cracks, and signs of wear. Replacesleeve (17) or (20) and bearing (16) or (9) if nicked, scratched, scored, cracked, or worn.

7. Measure inside diameter of bearings (9) and (16). Replace bearing (9) or (16) if inside diameter is

greater than 1.126 in. (2.860 cm).8. Inspect bearings (9) and (16) for nicks, scratches, pitting, scores, or cracks. Replace if nicked,

scratched, pitted, scored, or cracked.

9. Inspect four studs (19) and twelve studs (11) for bends or stripped threads. Replace stud(s) (19)or (11) if bent or threads are stripped.

10. Inspect turn angle screw (7) and nut (6) for damage. Replace turn angle screw (7) and nut (6) if damaged.

STEERING KNUCKLE INSTALLATION1. Install left and right steering knuckles (10) on pins (18) with studs (19) facing up.

2. Install sleeve (17), plate (15), and bearing (16) on left and right steering knuckles (10) with twonew lockwashers (12) and screws (13). Tighten screws (13) 116149 lb-ft (157202 N m).

3. Install sleeve (20), bearing (9), and spacer (8) on left and right steering knuckles (10).NOTE

Perform steps 4 and 5 for right steering knuckle. Perform step 6for left steering knuckle.

4. Install plate (24) with four new lockwashers (25) and screws (22) on steering knuckle (10). Tightenscrews (22) 116149 lb-ft (157202 N m).

5. Install lubrication fitting (23) on plate (24) and lubrication fitting (14) on plate (15).

6. Install lubrication fitting (4) on steering arm (5).

STEERING ARM INSTALLATION1. Install four new bushings (1) on steering arm (5).

2. Install steering arm (5) on four studs (19) with four new lockwashers (3) and nuts (2). Tightennuts (2) 130167 lb-ft (176226 N m).


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2322

24

8

9

18

25

20

1

2

3

4

5

8

920

19

18

21

10

11

13

14

15

16

17

18

12

6

7

LEFT SIDE

RIGHT SIDE10

11

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END PLAY TEST1. Install dial indicator on front axle housing (3) so measuring point touches steering arm mounting

plate (2).2. Install lever and jack stand under steering knuckle (1).

3. Pry upward with lever and support and observe dial indicator. Correct reading is 0.0040.014 in.(0.1020.356 mm).

NOTE

If dial indicator reading is correct, proceed to step 14

Perform steps 4 through 13 if dial indicator reading isincorrect.

Steps 4 through 6 apply to left steering knuckle.

Step 7 applies to right steering knuckle.

4. Remove lubrication fitting (6), four nuts (4), and lockwashers (5) from steering arm (7). Discardlockwashers (5).

5. Tap steering arm (7) at point A to loosen steering arm (7).

6. Remove steering arm (7) from steering knuckle (1).

7. Remove lubrication fitting (11), four screws (10), lockwashers (12), and plate (2) from steering knuckle (1). Discard lockwashers (12).

8. Remove spacer (8) from left and right steering knuckles (1).NOTE

If dial indicator reading was less than 0.004 in.(0.102 mm), install smaller spacer.

If dial indicator reading was more than 0.014 in.

(0.356 mm), install larger spacer.9. Install spacer (8) on left and right steering knuckles (1).

NOTE

Step 10 applies to right steering knuckle.

Steps 11 and 12 apply to left steering knuckle.

10. Install plate (2), four new lockwashers (12), screws (10), and lubrication fitting (11) on steering knuckle (3). Tighten screws (10) 116149 lb-ft, (157202 N m).

11. Install steering arm (7) on four studs (9) with four new lockwashers (5) and nuts (4). Tightennuts (4) 130167 lb-ft (176226 N m).


13. Check endplay (steps 1 through 3).

14. Install drag link (WP 0195 00).

15. Install tie rod (WP 0194 00).

16. Install steering knuckle boot (WP 0145 00) .

17. Install front axle shaft (WP 0142 00) .

18. Lubricate all components with lubricating oil, GO 80/90 (WP 0020 00) .

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1

12

10

2

8

11

1

8

9

4

56

7

1

2

3

POINT A

LEFT SIDE RIGHT SIDE

JACK STANDS

LEVER

DIAL INDICATOR

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TURN ANGLE SCREW ADJUSTMENT1. Count number of threads showing on screw (2) above nut (3) and record.

2. Break welds and remove screw (2) and nut (3) from steering knuckle (4). Discard screw (2) and nut (3).3. Install new nut (3) and new screw (2) on steering knuckle (4) with same number of threads

showing above nut (3) as in step 1.NOTE

Ensure wheels are in straight position.

4. Place wheel alignment device 3 in. (7.6 cm) from outer tire surface and place turning radius gaugeagainst outer tire surface.

5. Align pointer with center of wheel (5) and zero degree mark on alignment device.

6. Turn wheel (5) outward and read degrees of travel. Correct travel is 27-28 degrees.

7. Adjust screw (2) until head contacts axle housing (1) and tighten nut (3) 94-120 lb-ft(127-163 N m).

WARNING

Wear hand protection at all times when working with heatedparts. Failure to do so may result in injury to personnel.

Eye protection must be worn during welding procedures.Failure to wear eye protection may result in injury topersonnel.

Welding procedures may produce poisonous fumes. Performwelding in well-ventilated areas. Failure to do so may resultin injury to personnel.

8. Tack weld nut (3) to screw (2) and steering knuckle (4) (TC 9-237).


END OF WORK PACKAGE

WHEEL ALIGNMENT DEVICE

5

2

1

3

4

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FORWARD-REAR AND REAR-REAR AXLE ASSEMBLY REPLACEMENTREMOVAL AND INSTALLATION

INITIAL SETUP:




(item 137, WP 0469 00)1-1/8-in. socket, 3/4-in. drive

(item 99, WP 0469 00)Breaker bar (item 8, WP 0469 00)Handle, socket wrench, 3/4-in. drive

(item 41, WP 0469 00)Hydraulic jack (item 47, WP 0469 00)Jack stands

Materials/PartsTwelve lockwashers (item 238, WP 0470 00)Four seal washers

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Documents