planetary axle wheel endsplanetary axle wheel ends maintenance manual 9k prc 425q prc 775p (with q...

Planetary Axle Wheel EndsMaintenance Manual 9K

PRC 425Q PRC 775P(with Q Plus™ Cam Brakes) PRC 775 W3H

PRC 425 W3H

PRC 775P

PRC 775 W3H

Revised 02-01$2.50

Service Notes

How to Order

Order items from AxleTech International.

Phone orders are also accepted by callingAxleTech International’s Customer Service Centerat 877-547-3907 or send a fax to 866-547-3987.

WARNING A WARNING indicates aprocedure that you mustfollow exactly to avoidserious personal injury.

CAUTION A CAUTION indicates aprocedure that you mustfollow exactly to avoiddamaging equipment orcomponents. Seriouspersonal injury can alsooccur.

This symbol indicates thatfasteners must betightened to a specifictorque.

NOTE: A NOTE indicates anoperation, procedure orinstruction that isimportant for properservice. A NOTE can alsosupply information thatwill help to make servicequicker and easier.

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This maintenance manual describes the correctservice and repair procedures for AxleTech planetary axle wheel ends. The informationcontained in this manual was current at time ofprinting and is subject to change without noticeor liability.

You must follow your company procedures whenyou service or repair equipment or components.You must understand all procedures andinstructions before you begin to work on a unit.Some procedures require the use of special toolsfor safe and correct service. Failure to use specialtools when required can cause serious personalinjury to service personnel, as well as damageequipment and components.

The instructions contained in this FieldMaintenance Manual are intended for use byskilled and experienced mechanicsknowledgeable in the installation, repair andreplacement of the AxleTech product describedherein. Installation, maintenance and replacementof such products require a high degree of skill andexperience. The consequences of improperinstallation, maintenance or replacement(including the use of inferior or substandardcomponents) are grave and can result in productfailure and resulting loss of control of the vehicle,possible injury to or death of persons and/orpossible future or additional axle damage.AxleTech does not authorize anyone other thanhighly skilled and experienced individuals toattempt to utilize the instructions contained in thisManual for the installation, maintenance orreplacement of the product described herein, andAxleTech shall have no liability of any kind fordamages arising out of (or in connection with)any other use of the information contained in thisManual.

AxleTech International uses the followingnotations to warn the user of possible safetyproblems and to provide information that willprevent damage to equipment and components.

Table of Contents

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

Section 1: Exploded ViewsPRC 425Q (with Q Plus™ Cam Brakes) ........................................................................................................2PRC 425 W3H .................................................................................................................................................3PRC 775P ........................................................................................................................................................4PRC 775 W3H .................................................................................................................................................5

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

Section 3: Disassembly

PRC 425Q (with Q Plus™ Cam Brakes) Planetary AxleRemoval – PRC 425 Q Plus™ Cam Brake Planetary Axle Wheel End.................................................8Brake DrumPlanetary Spider Assembly...................................................................................................................10Cam Brakes.............................................................................................................................................11Spindle and Brake Spider

PRC 425 W3H Wet Disc BrakeRemoval – PRC 425 W3H Wet Disc Brake Wheel End.........................................................................13Preliminary DisassemblyPlanetary Spider Assembly...................................................................................................................14Wheel End ..............................................................................................................................................15Spindle and Piston HousingWet Disc Brakes .....................................................................................................................................16

PRC 775P Planetary AxleRemoval – PRC 775P Planetary Axle Wheel End.................................................................................17Brake DrumPlanetary Spider Assembly...................................................................................................................19Cam Brakes.............................................................................................................................................20Spindle and Brake Spider

PRC 775 W3H Wet Disc BrakeRemoval – PRC 775 W3H Wet Disc Brake Wheel End........................................................................21Preliminary DisassemblyPlanetary Spider Assembly...................................................................................................................22Wheel End ..............................................................................................................................................23Spindle and Piston HousingWet 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 FinishClean Axle AssembliesDry Cleaned PartsPrevent CorrosionInspect Parts.................................................................................................................................................26Inspect Tapered Roller BearingsInspect the Bevel Pinion and Ring Gear Sets............................................................................................27Inspect the Main Differential Assembly.....................................................................................................28Inspect the Axle ShaftsInspect the YokeInspect the BrakesRepair or Replace PartsRepair WeldingApply Silicone Gasket Material ..................................................................................................................29

Section 5: Assembly

PRC 425Q (with Q Plus™ Cam Brakes) Planetary AxlePRC 425Q (with Q Plus™ Cam Brakes) Planetary Axle Wheel End ..................................................30Prepare Parts for AssemblyAssemblySpindle, Brake Spider and BrakeWheel End..............................................................................................................................................31Adjust the Wheel Bearing Preload ......................................................................................................32Planetary Spider and Gearing AssemblyPlanetary Spider Assembly ..................................................................................................................33

PRC 425 W3H Wet Disc BrakeAssembly – PRC 425 W3H Wet Disc Brake Wheel End ......................................................................34Prepare Parts for AssemblySpindle and Piston Housing to the Axle HousingWet Disc BrakesWheel End..............................................................................................................................................35Adjust the Wheel Bearing Preload ......................................................................................................36Planetary Spider and Gearing Assembly ............................................................................................37Planetary Spider Assembly ..................................................................................................................38Fill Wet Disc Brakes with Hydraulic Fluid

PRC 775P Planetary AxleAssembly – PRC 775P Planetary Axle Wheel End ..............................................................................39Prepare Parts for AssemblySpindle, Brake Spider and BrakeWheel End..............................................................................................................................................40Adjust the Wheel Bearing Preload ......................................................................................................41Planetary Spider and Gearing Assembly ............................................................................................42Planetary Spider Assembly

Table of Contents

PRC 775 W3H Wet Disc BrakeAssembly – PRC 775 W3H Wet Disc Brake Wheel End ......................................................................43Prepare Parts for AssemblySpindle and Piston Housing to the Axle HousingWet Disc BrakesWheel EndAdjust the Wheel Bearing Preload ......................................................................................................45Planetary Spider and Gearing Assembly ............................................................................................46Planetary Spider AssemblyFill Wet Disc Brakes with Hydraulic Fluid

Section 6: SpecificationsPRC 425 Q Plus™ Wheel End Torque Chart ..............................................................................................48PRC 425 W3H Wheel End Torque Chart ....................................................................................................49PRC 775P Wheel End Torque Chart ..........................................................................................................50PRC 775 W3H Wheel End Torque Chart ....................................................................................................51Lubrication Specifications ..........................................................................................................................52Lubrication ScheduleWet Disc Brake Coolant Specifications......................................................................................................53Sump and Forced Cooling Systems With Hub SealsCoolant Change IntervalsHydraulic Fluid Specifications

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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 Brake Drum2 Setscrew3 Planetary Spider4 Machine Screw5 Pinion Shaft6 Outer Thrust Washer7 Planetary Pinion Gear8 Inner Thrust Washer9 Thrust Button

10 Snap Ring11 Planetary Sun Gear12 Thrust Washer13 Planetary Ring Gear14 Adjusting Nut Dowel Pin15 Adjusting Nut16 Outer Bearing Cone17 Outer Bearing Cup18 O-Ring

19 Wheel Nut20 Hub21 Wheel Stud22 Inner Bearing Cup23 Inner Bearing Cone24 Oil Seal Assembly25 Cap Screw (3/4-10 x 2.75)26 Flat Washer27 Spindle

PRC 425Q (with Q Plus™ Cam Brakes)

1

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3

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1

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1 Magnetic Drain/Fill Plug2 Setscrew3 Planetary Spider4 Thrust Button5 Snap Ring6 Planetary Sun Gear7 Thrust Washer8 Planetary Ring Gear9 Pin

10 Adjusting Nut

11 Flat Washer12 Capscrew13 Snap Ring14 Inner Thrust Washer15 Planetary Pinion Gear16 Outer Thrust Washer17 Planetary Pinion Shaft18 Outer Bearing Cone19 Outer Bearing Cup20 O-Ring

21 Wheel Nut22 Hub23 Wheel Stud24 Face Seal Assembly25 Inner Bearing Cup26 Inner Bearing Cone27 Oil Seal Assembly28 Spindle

PRC 425 W3H

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1 Wheel Nut2 Brake Drum3 Magnetic Drain Fill Plug4 Planetary Spider5 Thrust Button6 Thrust Button7 Snap Ring8 Planetary Sun Gear9 Thrust Washer

10 Planetary Ring Gear11 Capscrew12 Lock

13 Planetary Ring Gear Hub14 Adjusting Nut15 Lock Ring16 Inner Thrust Washer17 Planetary Pinion Gear18 Outer Thrust Washer19 Pinion Shaft

19A O-Ring (on pinion shaft)20 Machine Screw21 Outer Bearing Cone22 Outer Bearing Cup23 O-Ring

24 Hub25 Wheel Stud26 Inner Bearing Cup27 Inner Bearing Cone28 Oil Seal Assembly29 Capscrew30 Flat Washer31 Spindle

PRC 775P

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1 Magnetic Drain Fill Plug2 Planetary Spider3 Thrust Button4 Thrust Button5 Snap Ring6 Planetary Sun Gear7 Thrust Washer8 Adjusting Nut9 Planetary Ring Gear

10 Capscrew11 Lock12 Planetary Ring Gear Hub

13 O-Ring14 Lock Ring15 Inner Thrust Washer16 Planetary Pinion Gear17 Outer Thrust Washer18 Pinion Shaft

18A O-Ring (on pinion shaft)19 Outer Bearing Cone20 Outer Bearing Cup21 Wheel Nut22 Wheel Stud23 Hub

24 Face Seal Assembly25 Inner Bearing Cup26 Inner Bearing Cone27 Oil Seal Assembly28 Capscrew29 Flat Washer30 Spindle

PRC 775 W3H

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Section 2Introduction

Description

Meritor’s PRC 425Q (with Q Plus™ cam brakes)and PRC 775P planetary axles incorporate a singlereduction carrier/differential assembly withhypoid gearing. They are equipped with the RS-145 carrier series. The final reduction is ofplanetary spur designed gearing built into thewheel hubs. The axles have only cast housings.Figure 2.1.

AxleTech planetary axles permit the hypoidgearing of the carrier and the axle shafts to carryonly a nominal torsional load. At the same time,they provide the highest practical numerical gearreduction at the wheels.

• The hypoid pinion and differential assembly ofthe first reduction supports the roller bearings.

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

• The positioning of the threaded adjusting ringsin the carrier leg and cap bores adjusts andmaintains the differential tapered bearingpreload.

Figure 2.1

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

• The planetary gears rotate on planetary shaftsthat are mounted on a spider. The planetarygear teeth in turn mesh with the teeth of thefloating ring gear.

• The hypoid gear set in the carrier transmitspower to the axle shafts and the sun gear ofthe final reduction, through the revolvingplanetary gears, and into the planetary spider.

• The planetary wheel ends on both the PRC 425and 775 are serviced almost identically for camor wet disc brakes.

• AxleTech does not service a carrier-mountedpark brake (if equipped).

• For the PRC 475 axle models, follow theinstructions for the PRC 775 wheel end.

PRC 425Q (with Q PLUS™ CAM BRAKES)

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Section 2Introduction

Identification

The exact axle model specification is shown onthe identification tag located on the axle housing. Figure 2.2.

SINGLE PLANETARY AXLESFigure 2.2

P R __ C 7 7 5 P 208

EXACTSPECIFICATION

R – RIGIDP – PLANETARY

LAST DIGIT:CARRIERDESIGNATIONFOR BASE MODELNUMBER

FIRST TWO OR THREEDIGITS: 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 CAM (Q PLUS™

IN AXLE 425)W3H — DURA-DISC® 14.2 in. (360 mm) WET DISC

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Section 3Disassembly

WARNING

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

Removal

PRC 425Q (with Q Plus™ CamBrakes) Planetary Axle Wheel End

WARNING

Block 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 beingserviced to keep the vehicle from moving.

3. Raise the vehicle so that the wheels of the axleto be serviced are off the ground. Support thevehicle with safety stands. Refer to the vehiclemaintenance manual for instructions onraising the vehicle.

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

5. Rotate the wheel ends so the magnetic drainplug in the planetary spider is at the bottom.Remove the plug. Drain and discard thelubricant from both wheel ends.

PRC 425Q (with Q Plus™ Cam Brakes) Wheel End Cross Section

OIL SEAL

INNERBEARING

WHEELSTUD OUTER

BEARING

ADJUSTINGNUT

PLANETARYGEAR

THRUSTBUTTON

SUNGEAR

SUN GEARTHRUSTWASHER

RING GEARPLANETARYSPIDER

MAGNETICDRAIN PLUG

MACHINESCREW

BRAKEDRUM

O-RINGSPINDLEAXLESHAFT

PLANETARYPINIONSHAFT

PIN

SETSCREW

9


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

WARNING

When 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 thespring to prevent the spring from activatingduring disassembly.

NOTE: If Meritor automatic slack adjusters areused, refer to Maintenance Manual 4B, AutomaticSlack Adjuster for the correct adjustmentprocedure. To order this publication, callArvinMeritor’s Customer Service Center at 800-535-5560.

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

WARNING

To 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 strapis damaged.

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

9. Use a lifting device to support the brake drum.Figure 3.1.

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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. With the lifting device, carefully remove thebrake drum. Figure 3.2.

12. Remove the five slotted head machinescrews that attach the planetary spider to thewheel hub.

Planetary Spider Assembly

• If only the planetary pinions are removed forinspection without removing the pinion shaft,proceed to Step 5.

WARNING

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



1. With a lifting device, remove the planetaryspider from the wheel hub. Set its largeflange side on a workbench.

2. Matchmark the outer ends of the pinionshafts and the planetary spider to aid inreassembly if the original pinion shafts areused.

3. Remove the setscrew from each of the pinion shafts.

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WARNING

Observe 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.

CAUTION

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

4. Use a press to remove the pinion shafts. If apress is not available, use a brass drift andmallet to drive out the shaft. Press or drivethe pinion shaft out toward the large flangeend of the planetary spider.

5. Remove the snap ring, inner thrust washer,planetary pinion and outer thrust washerfrom each pinion shaft.

6. Remove the axle shaft thrust button only if itis worn. Press it out TOWARD the large endof the planetary spider.

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

7. Remove the axle shaft, planetary sun gearand snap ring assembly.

8. If necessary, remove the snap ring from theaxle shaft to allow for the removal of the sungear and sun gear thrust washer.

9. If necessary, remove the sun gear thrustwasher from the end of the planetary ringgear.

10. Remove the planetary ring gear.

11. Remove the wheel bearing adjusting nut.

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Figure 3.2

11


Figure 3.3

CAUTION

The outer bearing cone will be loose as you passit over the end of the spindle. Hold the conesecurely to avoid dropping it and damaging the cone.

12. Remove the wheel hub assembly. The wheelbearings and oil seal will come off with thewheel hub.

• If replacing the hub oil seal and bearings:continue with Steps 13 through 16.

CAUTION

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

13. Remove the wheel hub oil seal from thewheel hub.

14. Remove the inner bearing cone.

15. Press out the outer bearing cup and innerbearing cup from the hub.

16. Remove and discard the O-ring from thewheel hub.

Cam Brakes

To disassemble the PRC 425Q (with Q Plus™ cambrakes), refer to Maintenance Manual No. 4, CamBrakes. To order this publication, callArvinMeritor’s Customer Service Center at 800-535-5560.

If it is necessary to remove the anchor pins,remove the brake dust shields for convenientaccess to the anchor pins.

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! Spindle and Brake Spider

WARNING



• 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 spiderfrom falling after all the mounting capscrewsare removed, use one of the followingprocedures:

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

B. Remove only two capscrews. Replace themwith two temporary M16 x 2.0 thread studsfour inches (102 mm) before the remainingcapscrews are removed. Figure 3.3.

• 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 thatmount the brake spider and spindle to the axlehousing.

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 loosenthe pilot fit and to overcome the adhesion dueto the cured gasket material in the flange joint.

13


PRC 425 W3H Wet Disc BrakeWheel End

WARNING


Preliminary Disassembly



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PRC 425 W3H Wheel End Cross Section




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

INNERBEARING

SUN GEARTHRUSTWASHER

THRUSTBUTTON

PLANETARYSPIDER

PLANETARYPINION SHAFT

MAGNETICDRAIN PLUG

PLANETARYGEAR

WHEEL HUB

FACE SEAL

SPINDLE

AXLE SHAFT

OIL SEAL

WET BRAKEPISTON HOUSING

WET BRAKEDISC HOUSING

O-RING

OUTERBEARING

SUN GEAR

ADJUSTINGNUT

PIN

WHEELSTUD

14



• If only the planetary pinions are removed forinspection without removing the pinion shaft,proceed to Step 5.

1. With a lifting device, remove the planetaryspider from the wheel hub. Set its large flangeside on a workbench.

2. Matchmark the outer ends of the pinion shaftsand the planetary spider to aid in reassemblyif the original pinion shafts are used.

3. Remove the setscrew from each of the pinion shafts.

WARNING



CAUTION


4. Use a press to remove the pinion shafts. If apress is not available, use a brass drift andmallet to drive out the shaft. Press or drive thepinion shaft out toward the large flange end ofthe planetary spider.

5. Remove the snap ring, inner thrust washer,planetary pinion and outer thrust washer fromeach pinion shaft.

6. Remove the axle shaft thrust button only if it isworn. Press it out TOWARD the large end ofthe planetary spider.


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

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8. If necessary, remove the snap ring from theaxle shaft to allow for the removal of the sungear and sun gear thrust washer.

9. If necessary, remove the sun gear thrustwasher from the end of the planetary ringgear.

10. Remove the planetary ring gear.

11. Mark the position of the wheel bearingadjusting nut. Remove the wheel bearingadjusting nut.

CAUTION

The outer bearing cone will be loose as you passit over the end of the spindle. Hold the conesecurely to avoid dropping it and damaging the cone.

12. Remove the outer bearing cone and wheelhub assembly with the brake driver splinesfrom the friction discs. The wheel bearingsand oil seal will come off with the wheel hub.

• If replacing the hub oil seal and bearing,continue with Steps 13 through 16.

CAUTION


13. Remove the wheel hub oil seal from thewheel hub.


15. If replacement of the wheel bearings isnecessary, press out the outer bearing cupand inner bearing cup from the hub.


!

!

CAUTION

Do 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.

5. Support the brake housing assembly. Removethe remaining capscrews.

6. Remove the brake housing assembly from thepiston 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. Evenlyturn the screws CLOCKWISE.

Spindle and Piston Housing

WARNING




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 DiscBrake with Dowel Pins/Model W3H (360 mm). CallAxleTech International’s Customer Service Centerat 877-547-3907 or send a fax to 866-547-3987.

You can also access maintenance and productinformation on AxleTech’s website atwww.axletech.com.

CAUTION

The face seal comes off with the hub. Do not setthe hub down on the face seal. Damage to theface seal can result. Remove the face seal fromthe hub.

1. Remove the face seal half from the hubassembly.

2. Remove the rest of the face seal from the brakehousing assembly.

CAUTION

The face seal comes off with the disc housing. Donot set the disc housing on the face seal. Damageto the face seal can result. Remove the face sealfrom the wet disc brake housing.

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

WARNING


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

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

!

!

!

16


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


• Install one stud at the one o’clockposition.

2. Remove the capscrews and washers thatsecure the piston housing and spindle to theaxle housing.

3. Remove the piston housing from the spindle.

4. Remove the spindle from the axle housing. Ifnecessary, tap lightly on the spindle to loosenthe pilot fit and to overcome the adhesion dueto the cured gasket material in the flange joint.Figure 3.4.

Wet Disc Brakes

Refer to Maintenance Manual MM-20195, WetDisc Brake with Dowel Pins/Model W3H (360 mm).Call AxleTech International’s Customer ServiceCenter at 877-547-3907 or send a fax to 866-547-3987.


Figure 3.4

17


PRC 775P Planetary Axle Wheel End

WARNING


Brake Drum



!




PRC 775P Wheel End Cross Section

INNERBEARING

OUTERBEARING

THRUSTBUTTON

SUN GEAR

WHEEL HUBO-RING

PLANETARYSPIDER

PLANETARYPINION GEAR

ADJUSTINGNUT

WHEELSTUD

HUB

SPINDLE

AXLE SHAFT

BRAKE DRUM

O-RING

18


6. If necessary, remove the magnetic drain plugfrom the bottom of the axle housing. Drainand discard the lubricant from the carriercenter section.

WARNING

When 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 thespring to prevent the spring from activatingduring disassembly.

NOTE: If Meritor automatic slack adjusters areused, refer to Maintenance Manual 4B, AutomaticSlack Adjuster, for the correct adjustmentprocedure. To order this publication, callArvinMeritor’s Customer Service Center at 800-535-5560.

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

WARNING




9. Use a lifting device to support the brakedrum. Figure 3.5.

!

!

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

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

12. Remove the five slotted head machinescrews that attach the planetary spider to thewheel hub.

Figure 3.5

19



WARNING




1. With a lifting device, remove the planetaryspider assembly from the wheel hub and set iton a workbench. Rest the spider on its largeflange end.

2. If the planetary ring gear did not remain withthe planetary spider assembly during theassembly’s removal, remove the ring gearfrom the planetary ring gear hub.

3. Mark the large ends of the planetary pinionshafts and the planetary spider to aid inreassembly if the original pinion shafts areused.

4. Place the planetary spider assembly on blockswith the large flange end facing UP. Removethe snap ring from each pinion shaft.

WARNING



CAUTION


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 thesmall end of the spider which faces DOWN.

!

!

!

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

7. If the axle shaft thrust button and/or ring gearsupport thrust buttons are worn and requirereplacement, place the planetary spider onblocks with the large flange end facingDOWN. Press them out toward the large endof the planetary spider.



9. Remove the snap ring from the axle shaft toallow for the removal of the sun gear fromthe axle shaft.

10. If necessary, remove the sun gear thrustwasher from the axle shaft.

11. If necessary, remove the sun gear thrustwasher from the end of the spindle.

12. Remove the two lock plate capscrews.Remove the lock plate from the planetaryring gear hub.


14. Remove the planetary ring gear hub. Theouter wheel bearing cone will remain on thering gear hub. If it is damaged, remove itfrom the hub.

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

20


CAUTION


17. Remove the hub oil seal.


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


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,remove the brake dust shields for convenientaccess to the anchor pins.

Spindle and Brake Spider

WARNING




!

! WARNING

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 brake spider fromfalling after all the mounting capscrews areremoved, use one of the following procedures:


B. Remove only two capscrews. Replace themwith two temporary M20 x 2.5 UNC threadstuds four inches (102 mm) long before theremaining capscrews are removed. Figure 3.6.


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

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 securethe 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 loosenthe pilot fit and to overcome the adhesion dueto the cured gasket material in the flange joint.

!

Figure 3.6

21



WARNING


Preliminary Disassembly



!




6. If necessary, remove the magnetic drain plugfrom the bottom of the axle housing. Drainand discard the lubricant from the carriercenter section.

PRC 775 W3H Wheel End Cross Section

WHEEL HUB O-RING

OUTER BEARING

PLANETARY GEAR

ADJUSTINGNUT

THRUSTBUTTON

PLANETARYPINION SHAFT

PLANETARYSPIDER

MAGNETICDRAIN PLUG

INNERBEARINGWET BRAKE

PISTON HOUSINGWET DISC BRAKEHOUSING FACE SEAL

O-RING

LOCK

SUN GEAR

SUN GEARTHRUST WASHER

RING GEAR HUB

SPINDLE

AXLE SHAFT

OIL SEAL WHEELHUB

WHEELSTUD

22



WARNING




1. With a lifting device, remove the planetaryspider assembly from the wheel hub and set iton a workbench. Rest the spider on its largeflange end.

2. If the planetary ring gear did not remain withthe planetary spider assembly during theassembly’s removal, remove the ring gearfrom the planetary ring gear hub.

3. Mark the large ends of the planetary pinionshafts and the planetary spider to aid inreassembly if the original pinion shafts areused.

4. Place the planetary spider assembly on blockswith the large flange end facing UP. Removethe snap ring from each pinion shaft.

WARNING



CAUTION


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 thesmall end of the spider which faces DOWN.

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

!

!

!

7. If the axle shaft thrust button and/or ring gearsupport thrust buttons are worn and requirereplacement, place the planetary spider onblocks with the large flange end facingDOWN. Press them out toward the large endof the planetary spider.



9. Remove the snap ring from the axle shaft toallow for the removal of the sun gear fromthe axle shaft.

10. If necessary, remove the sun gear thrustwasher from the axle shaft.

11. If necessary, remove the sun gear thrustwasher from the end of the spindle.

12. Remove the two lock plate capscrews.Remove the lock plate from the planetaryring gear hub.


14. Remove the planetary ring gear hub. Theouter wheel bearing cone will remain on thering gear hub. If it is damaged, remove itfrom the hub.

15. Remove the wheel hub with brake driversplines from the friction discs. The hub oil sealand inner bearing assembly will remain in the hub.

• If replacing the hub oil seal and bearings,continue with Steps 17 through 19.

CAUTION


17. Remove the hub oil seal.


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


!

CAUTION



5. Support the brake housing assembly. Removethe remaining capscrews.

6. Remove the brake housing assembly from the piston housing and set it on a table withthe discs facing up to prevent the discs fromfalling out.

7. Remove the four shoulder bolts from thepiston and 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. Evenlyturn the screws CLOCKWISE.

Spindle and Piston Housing

WARNING




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



CAUTION

The face seal comes off with the hub. Do not setthe hub down on the face seal. Damage to theface seal can result. Remove the face seal fromthe hub.

1. Remove the face seal half from the hubassembly.

2. Remove the rest of face seal from the brakehousing assembly.

CAUTION

The face seal comes off with the disc housing. Donot set the disc housing on the face seal. Damageto the face seal can result. Remove the face sealfrom the disc housing.

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

WARNING


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

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

!

!

!

24


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


• Install one stud at the one o’clockposition.

2. Remove the capscrews and washers thatsecure the piston housing and spindle to theaxle housing.

3. Remove the piston housing from the spindle.

4. Remove the spindle from the axle housing. Ifnecessary, tap lightly on the spindle to loosenthe pilot fit and to overcome the adhesion dueto the cured gasket material in the flange joint. Figure 3.7.

Wet Disc Brakes



Figure 3.7

25

Section 4Prepare Parts for Assembly

WARNING


Clean Ground or Polished Parts

WARNING

Solvent 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 orpolished metal parts. Hot solution tanks orwater and alkaline solutions will damage theseparts. Isopropyl alcohol, kerosene or diesel fuelcan 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,to clean ground or polished parts or surfaces.NEVER USE GASOLINE.

2. Remove gasket material from parts. Take carenot to damage ground surfaces.

3. DO NOT clean ground or polished parts in ahot solution tank, water, steam or alkalinesolution.

!

!

! Clean Parts with a Rough Finish

1. Use a cleaning solvent or a hot solution tankwith a weak alkaline solution to clean partswith a rough finish.

2. Leave parts in the hot solution tank until theyare completely cleaned and heated. When theparts are clean, remove them from the tank.

3. Wash the parts with water until youcompletely remove the alkaline solution.

Clean Axle Assemblies

• A complete axle assembly can be steamcleaned on the outside to remove dirt.

• Before the axle is steam cleaned, close or put acover over all the openings in the axleassembly. Examples of openings are thebreathers or vents in air chambers.

CAUTION

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

Dry Cleaned Parts

• Immediately after cleaning, use clean paper,rags or compressed air to dry parts.

Prevent Corrosion

NOTE: 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 preventscorrosion.

!

26


Inspect Parts

• It is important to carefully inspect all parts forwear and damage before you assemble theaxle carrier.

• Replace damaged parts.

Inspect Tapered Roller Bearings

Inspect the cup, cone, rollers and cage of alltapered roller bearings in the assembly. If any ofthe following conditions exist, replace thebearing:

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

• The centers of the large diameter end of therollers are worn to a sharp edge. Figure 4.1.

• A visible roller groove is worn in the cup orcone inner race surfaces. You can see thegroove at the small or large diameter ends ofboth parts. Figure 4.2.

Figure 4.2

Figure 4.1WORN RADIUS

WORN SURFACE

CRACK WEAR GROOVES

27


• Spalling or flaking is present on the cup andcone inner race surfaces that touch the rollers.Figure 4.5.

Inspect the Bevel Pinion and RingGear Sets

CAUTION

The bevel drive pinions and ring gears aremachined in matched sets. When a drive pinionor ring gear of a bevel set needs to be replaced,both drive gear and pinion must be replaced atthe same time. A higher stress on the originalparts and early failure of the entire assembly willresult if a new part is used in combination withparts that are older or worn.

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

2. Verify the condition of the bearing cone seatsand spline on the pinion shaft.

!

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

• Bright wear marks are present on the outersurface of the roller cage. Figure 4.3.

• Etching and pitting is present on the rollers andon surfaces of the cup and cone inner race thattouches the rollers. Figure 4.4.

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,to clean the interior of the main differentialassembly. NEVER USE GASOLINE.

2. Use the left shaft to rotate one side gear.Replace the differential assembly if you seeany binding.

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

Inspect the Axle Shafts

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

Inspect the Yoke

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

Inspect the Brakes

Refer to Maintenance Manual MM-20195, WetDisc Brake with Dowel Pins/Model W3H(360 mm). Call AxleTech International’s CustomerService Center at 877-547-3907 or send a fax to866-547-3987.


Repair or Replace Parts

Replace 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 gasketmaterial where required when the axle isassembled.

• Remove nicks, marks and burrs from partshaving machined or ground surfaces. Use afine file, India stone, emery cloth or crocuscloth for this purpose.

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

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

Repair Welding

WARNING

Do not weld repair, heat, bend or reconditionaxle components. 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 damagedor worn. Do not weld repair or recondition.

!

29


5. Assemble the components immediately topermit the gasket material to compress evenlybetween parts. Tighten the fasteners to therequired torque value for that size fastener usingan “X” torquing pattern. Refer to the TorqueChart in Section 6.

6. Wait 20 minutes before filling the assembly withlubricant.

Apply Silicone Gasket Material

AxleTech Specifications:

• ThreeBond 1216

• Loctite 5699

WARNING

When 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 thesurfaces of both components.

2. Clean the surfaces where the liquid gasketmaterial will be applied. Remove all the oil,grease, dirt and moisture.

3. Thoroughly dry both surfaces.

CAUTION

The 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. Apply a 0.125 inch (3.18 mm) diametercontinuous bead of silicone gasket materialaround one surface. Also apply the gasketmaterial around the edge of all the fastener holeson that surface. Figure 4.6.

!

!

Figure 4.6

0.125" (3.18 MM)DIAMETERSILICONE GASKETMATERIAL BEAD

30

Section 5Assembly

WARNING


PRC 425Q (with Q Plus™ CamBrakes) Planetary Axle Wheel End

Prepare Parts for Assembly

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

Assembly

Spindle, Brake Spider and Brake

1. Install two temporary studs (M16 - 2.0 threads,approximately four inches long) into the axlehousing flange. Install the studs at the eleveno’clock and one o’clock positions. Figure 5.1.

! WARNING

When 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.

2. Apply a 0.125 inch (3.18 mm) diametercontinuous bead of silicone gasket materialaround the flange mounting face of either theaxle housing or the spindle. Also apply thegasket material around the edge of all thefastener holes on that surface. Figure 5.2.

3. Install the spindle onto the axle housing.

4. Install the brake spider onto the spindle.

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

6. Remove the two temporary studs.

7. Install the remaining spindle mountingcapscrews and washers. Tighten all capscrewsto 200-260 lb-ft (270-350 N•m).

!

Figure 5.1

Figure 5.2

GASKETMATERIAL

31

Section 5Assembly

NOTE: Replace the camshaft bushing and greaseseals before the camshaft bracket is installedonto the brake spider. Refer to MaintenanceManual 4, Cam Brakes. To order this publication,call ArvinMeritor’s Customer Service Center at 800-535-5560.

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

9. Install the four mounting capscrews andwashers. Tighten the capscrews to 85-115 lb-ft (115-156 N•m).

NOTE: Refer to Maintenance Manual 4, CamBrakes; and Maintenance Manual 4B, AutomaticSlack Adjuster, to install the brake camshaft,anchor pin components, brake shoes, brakesprings, slack adjusters and related parts. Toorder this publication, call ArvinMeritor’sCustomer Service Center at 800-535-5560.

10. Install the brake camshaft bracket clamparound the bracket tube. Install the twocapscrews and washers that mount theclamp to the axle housing. Tighten thecapscrews to 35-50 lb-ft (47-68 N•m).

11. Install the air chamber-to-bracket mountingnuts. Tighten the nuts to 100-115 lb-ft (136-156 N•m).

12. Attach the chamber push rod yoke to theslack adjuster. Tighten the yoke jam nut to25-50 lb-ft (34-68 N•m).

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

Wheel End

1. Press the new inner and outer bearing cupsinto the wheel hub.

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

3. Apply axle gear lubricant to the bearingrollers and install the inner wheel bearingcone.

CAUTION

• Do not damage the hub oil seal bore surface inthe wheel hub. Damage to this surface willresult in oil leakage after assembly.

• Apply a light film of non-hardening sealant tothe hub bore surface to eliminate oil leakagefrom the outer diameter of the seal.

• The hub oil seal is a “unitized” oil seal. Therotating seal lips are internal. The rubber ribsin the bore of the seal seat onto the spindlejournal surface for static sealing. The ribs mustnot be cut or damaged to avoid an oil leak path.

4. Use the correct oil seal driver to install thewheel hub oil seal. Press the seal into the hubuntil the standout from the hub machined faceis 0.34 inch (8.64 mm). Figure 5.3.

NOTE: Use a Permatex coating to seal againstleaks around the hub oil seal. Leaks would resultin requiring disassembly, should leak be notedafter the final axle assembly.

5. Apply a light, uniform coating of Permatex tothe wheel hub bore.

6. Apply a light film of axle lubricant to the hub oilseal rubber ribs in the oil seal bore.

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

!

Figure 5.3

0.34 inch(8.64 mm)

32

Section 5Assembly

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

9. Install the wheel bearing adjusting nut. Thedowel pin in the nut must face OUT.

Adjust the Wheel Bearing Preload

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

WARNING


1. Install the wheel bearing adjusting nut.Tighten the nut to 400 lb-ft (542 N•m).

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

3. Tighten the nut to 400 lb-ft (542 N•m) again.

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

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

WARNING

Carefully align the adjusting nut dowel pinwithin a ring gear tooth spline to avoid damageto the pin. A damaged dowel pin will cause theadjusting nut to back off and loosen the wheelduring vehicle operation. This can result inserious personal injury and damage tocomponents.

6. Carefully align the adjusting nut dowel pinwithin a ring gear tooth spline to avoiddamage to the dowel pin. Tighten theadjusting nut to produce the proper alignment.Do not back off the adjusting nut.

7. Install the planetary ring gear onto the spindle.The dowel pin in the adjusting nut must beinstalled in the hole in the ring gear face toallow the ring gear to seat against theadjusting nut.

!

!

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

9. Install the sun gear thrust washer. Thewasher tangs must engage the holes in thering gear.

10. Install the planetary sun gear and snap ringonto the axle shaft.

11. Install the axle shaft and sun gear assembly.For correct installation:

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

• The sun gear must make contact with thethrust washer.

• The thrust washer tangs must be properlyinstalled in the ring gear hub holes.

12. Install the O-ring on the wheel hub at thebase of the flange.

Planetary Spider and Gearing Assembly

WARNING

When 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. If thrust button replacement is required, usethe procedure below. If the thrust button is notto be changed, proceed to Step 2.

A. Apply liquid gasket material to the axleshaft thrust button shaft before pressing itinto the spider.

B. Press the new axle shaft thrust button intothe planetary spider.

C. Apply a film of non-hardening sealant tothe spider pinion shaft bores.

!

33

Section 5Assembly

2. Press the pinion shafts into the bores from theinner cavity end of the spider. Press the non-coated end of the pinion shaft into the spideruntil the end of the shaft is 2.085-2.080 inches(52.96-52.83 mm) from the inside face of thespider. Figure 5.4.

3. Install a setscrew into each pinion shaft.Tighten each setscrew to 35 lb-ft (47 N•m). Fornew pinion shafts (if replaced), machine a holefor the setscrew in each shaft.

A. Drill a 0.313 inch (8 mm) diameter hole 0.25 inch (6.4 mm) deep into the pinionshaft.

B. Carefully pass the drill through the 0.375 inch-16 tapped hole in the planetaryspider boss.

C. Install the setscrew and tighten it to 35 lb-ft(47 N•m).

4. Apply gear lubricant to the planetary pinionbores and to the pinion shaft journals.

5. Install the outer thrust washer with the tangengaged into the slot in the spider.

NOTE: If the original planetary pinions are used,verify that the gear bores are smooth and free ofany surface damage.

6. Install the planetary pinion, inner thrustwasher and snap ring.

7. Apply liquid gasket material on the wheel hubO-ring and the adjacent area.


NOTE: For correct installation, the planetarypinions must contact both the sun gear and thering gear before installation.

1. Install the planetary spider and gearingassembly onto the wheel hub.

2. Install the five slotted head machine screwsthat attach the planetary spider to the wheelhub. Hand tighten the screws. Seat the head ofeach screw below the surface of the spiderflange.

3. Install the brake drum over the wheel studsuntil the drum seats onto the planetary spiderflange.

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

NOTE: The PRC 425Q (with Q Plus™ Cam Brakes)axle has a common oil level between the carrierand the wheel ends. Three locations must befilled. The vehicle must be on a level surfacewhen filling. Fill to the bottom of each fillplughole. Wait and allow the oil to flow throughthe axle. Check the oil level again after severalminutes and fill to the specified level if necessary.

5. Add the correct axle lubricant into each wheelend through the fill/level hole in the planetaryspider at the horizontal position (3 or 9o’clock).

6. Add the correct lubricant to the axle housingbowl area.

7. Apply sealant to the threads of the fill/levelplugs.

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

Figure 5.4 ASSEMBLE 3SETSCREWSAS SHOWN

2.085-2.080"(52.96-52.83 mm)

0.3125" (7.94 mm)DIAMETER-0.250 DEEPONE HOLEEACH SHAFT

PRESS IN 3SHAFTS TODIMENSIONSHOWN

34

Section 5Assembly




Spindle and Piston Housing to the Axle Housing

1. Install two temporary studs (M20 x 2.5threads, approximately four inches long) intothe axle housing flange. Install the studs at theeleven o’clock and one o’clock positions.Figure 5.5.

WARNING

Take 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.

2. Clean and inspect the spindle and pistonhousing for damage. Apply a small, twomillimeter bead of Q48 (Loctite 518) near theOD of the spindle flange, on both sides of thespindle flange.

3. 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 toachieve 370-480 lb-ft (500-650 N•m) bolt torque.Install 10 mm x 60 mm long assembly studsinto the four M8 x 1.25 thread holes in thepiston cover.

Wet Disc Brakes

To assemble the PRC 425 W3H wet disc brakes,refer to Maintenance Manual MM-20195, 360 mmWet Disc Brakes. To order this publication, callAxleTech International’s Customer Service Centerat 877-547-3907 or send a fax to 866-547-3987.

NOTE: To continue assembling the PRC 425 W3Hwet disc brake wheel end, continue with thefollowing steps.

!

Figure 5.5

Wheel End

WARNING


1. Clean and inspect the piston for damage,inspect the piston grooves to ensure nocontaminants remain in the grooves.

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

WARNING


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 pistonover the assembly studs and push the pistoninto the piston housing until it bottoms out.

4. Remove and store the four assembly studs.

5. Install washers and springs on the fourshoulder bolts.

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

NOTE: The brake housing has TOP identified witha raised lug.

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

8. Place the brake housing on an assemblybench. Assemble the eight dowels into theslots in the brake housing.

!

!

35

Section 5Assembly

CAUTION

Do 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 groovesin a stack so that they can be assembled thisway inside 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’sslots.

11. Repeat these steps until completing theassembly stack of discs. Realign all the frictiondiscs’ splines and grooves.

WARNING


12. Apply a small, continuous two millimeterbead of Loctite 518 onto the mounting face ofthe brake housing. Carefully lift the brakehousing assembly (lug on TOP) and install itonto the piston housing that is alreadymounted on the axle.

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

!

!


WARNING


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






WARNING

Carefully align the adjusting nut dowel pin withina ring gear tooth spline to avoid damage to thepin. A damaged dowel pin will cause theadjusting nut to back off and loosen the wheelduring vehicle operation. This can result inserious personal injury and damage tocomponents.

6. Carefully align the adjusting nut dowel pinwithin a ring gear tooth spline to avoiddamage to the dowel pin. Tighten theadjusting nut to produce the properalignment. Do not back off the adjusting nut.

7. Install the planetary ring gear onto thespindle. The dowel pin in the adjusting nutmust be installed in the hole in the ring gearface to allow the ring gear to seat against theadjusting nut.

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

9. Install the sun gear thrust washer. The washertangs must engage the holes in the ring gear.

!

!

36

Section 5Assembly

NOTE: Use a Permatex coating to seal againstleaks around the hub oil seal. Leaks would resultin requiring disassembly, should the leak benoted after the final axle assembly.

14. Install half of the face seal into the brakehousing by using a Caterpillar assembly toolto properly position the O-ring and steel ringassembly beyond the lip and into the taperedbore in the brake housing.

15. Measure the height of the metal face abovethe housing to ensure the tolerance is within1 mm variation.

16. Clean and inspect the hub.

17. Install the inner and outer bearing cups intothe hub. Install the inner bearing cone andspindle seal into the hub. Press the spindleseal flush with the shoulder in the hub bore.



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

19. Install the second half of the face seal into thehub and cup assembly by using a Caterpillarassembly tool to properly position the O-ringand steel ring assembly beyond the lip andinto the tapered bore in the hub.

CAUTION

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

20. Apply a light coating of lubricant to the twomating surfaces of the face seal’s steel ringsonly. Do not allow the lubricant to contact the O-ring. Use the same lubricant that was usedon the coolant side.

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

22. Install the outer bearing cone on the spindle.Install the spindle nut on the spindle. Rotate thehub while tightening the nut as recommendedin the wheel bearing adjustment procedure.

23. Perform the pressure test.

!

37

Section 5Assembly

3. Install a setscrew into each pinion shaft.Tighten each setscrew to 35 lb-ft (47 N•m). Fornew pinion shafts (if replaced), machine a holefor the setscrew in each shaft.

A. Drill a 0.313 inch (8 mm) diameter hole 0.25 inch (6.4 mm) deep into the pinionshaft.

B. Carefully pass the drill through the 0.375 inch-16 tapped hole in the planetaryspider boss.

C. Install the setscrew and tighten it to 35 lb-ft(47 N•m).

4. Apply gear lubricant to the planetary pinionbores and to the pinion shaft journals.

5. Install the outer thrust washer with the tangengaged into the slot in the spider.


6. Install the planetary pinion, inner thrustwasher and snap ring.

Figure 5.6 ASSEMBLE 3SETSCREWSAS SHOWN

2.085-2.080"(52.96-52.83 mm)

0.3125" (7.94 mm)DIAMETER-0.250 DEEPONE HOLEEACH SHAFT

PRESS IN 3SHAFTS TODIMENSIONSHOWN






12. Install the O-ring on the wheel hub at thebase of the flange.


1. If thrust button replacement is required, usethe procedure below. If the thrust button isnot to be changed, proceed to Step 2.

WARNING


A. Apply liquid gasket material to the axleshaft thrust button shaft before pressing itinto the spider.

B. Press the new axle shaft thrust button intothe planetary spider.

C. Apply a film of non-hardening sealant tothe spider pinion shaft bores.

2. Press the pinion shafts into the bores from theinner cavity end of the spider. Press the non-coated end of the pinion shaft into the spideruntil the end of the shaft is 2.085-2.080 inches(52.96-52.83 mm) from the inside face of thespider. Figure 5.6.

!

NOTE: The PRC 425 axle has a common oil levelbetween the carrier and the wheel ends. The wetdisc brakes must also be filled separately. Fivelocations must be filled. The vehicle must be on alevel surface when filling. Fill to the bottom ofeach fill plughole. Wait and allow the oil to flowthrough the axle. Check the oil level again afterseveral minutes and fill to the specified level ifnecessary.

5. Add the correct axle lubricant into each wheelend through the fill/level hole in the planetaryspider at the horizontal position (three or nineo’clock).


7. Apply sealant to the threads of the fill/levelplugs.

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

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 oilexits the lower plug (above the three or nineo’clock position). Install the lower plug and addtwo more liters of oil through the top plug.

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

NOTE: Brake coolant inlet is connected to the0.875"-14 UNF O-ring plug at the top position ofthe brake 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 the air from the brakeactuation system.

38

Section 5Assembly




2. Install the five slotted head machine screwsthat attach the planetary spider to the wheelhub. Hand tighten the screws. Seat the head ofeach screw below the surface of the spiderflange. Figure 5.7.

3. Install the brake drum over the wheel studsuntil the drum seats onto the planetary spiderflange.


Figure 5.7

39

Section 5Assembly

WARNING


2. Apply a 0.125 inch (3.18 mm) diametercontinuous bead of silicone gasket materialaround the flange mounting face of either theaxle housing or the spindle. Also apply thegasket material around the edge of all thefastener holes on that surface.

3. Align the flange flats. Install the spindle ontothe axle housing. Figure 5.9.

4. Install the brake spider onto the spindle.

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

6. Remove the two temporary studs.

7. Install the remaining spindle mountingcapscrews and washers. Tighten all capscrewsand washers to 370-480 lb-ft (500-650 N•m).

!PRC 775P Planetary Axle Wheel End



Spindle, Brake Spider and Brake

WARNING


1. Install two temporary studs (M20 - 2.5 threads,approximately four inches long) into the axlehousing flange. Install the studs at the eleven o’clock and one o’clock positions. Figure 5.8.

!

Figure 5.8

Figure 5.9

GASKETMATERIAL

3. Apply axle gear lubricant to the bearingrollers and install the inner wheel bearingcone.

CAUTION

• Do not damage the hub oil seal bore surfacein the wheel hub. Damage to this surface willresult in oil leakage after assembly.

• Apply a light film of non-hardening sealant tothe hub bore surface to eliminate oil leakagefrom the outer diameter of the seal.

• The hub oil seal is a “unitized” oil seal. Therotating seal lips are internal. The rubber ribsin the bore of the seal seat onto the spindlejournal surface for static sealing. The ribsmust not be cut or damaged to avoid an oilleak path.

4. Use the correct oil seal driver to install thewheel hub oil seal. Press the seal into the hubuntil the standout from the hub machinedface is 0.34 inch (8.64 mm). Figure 5.10.

!

40

Section 5Assembly

Figure 5.10

0.34 inch(8.64 mm)

NOTE: Replace the camshaft bushing and greaseseals before the camshaft bracket is installedonto the brake spider. Refer to MaintenanceManual 4, Cam Brakes. To order this publication,call ArvinMeritor’s Customer Service Center at 800-535-5560.

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

9. Install the four mounting capscrews andwashers. Tighten the capscrews to 85-115 lb-ft (115-156 N•m).

NOTE: Refer to Maintenance Manual 4, CamBrakes; and Maintenance Manual 4B, AutomaticSlack Adjuster, to install the brake camshaft,anchor pin components, brake shoes, brakesprings, slack adjusters and related parts. Toorder this publication, call ArvinMeritor’sCustomer Service Center at 800-535-5560.

10. Install the brake camshaft bracket clamparound the bracket tube and install the twocapscrews and washers that mount theclamp to the axle housing. Tighten thecapscrews to 35-50 lb-ft (47-68 N•m).

11. Install the air chamber-to-bracket mountingnuts. Tighten the nuts to 100-115 lb-ft (136-156 N•m).

12. Attach the push rod yoke to the slackadjuster. Tighten the yoke jam nut to 25-50 lb-ft (34-68 N•m).

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

Wheel End

CAUTION


1. Press the new inner and outer bearing cupsinto the wheel hub.

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

!



6. Apply a light film of axle lubricant to the huboil seal rubber ribs in the oil seal bore.

7. Install the wheel hub, inner bearing and oilseal assembly onto the spindle. Keep the hubassembly aligned with the spindle.

8. Apply axle lubricant to the outer bearingcone rollers. Install the outer bearing coneonto the planetary ring gear hub.

9. Install the ring gear hub and bearingassembly onto the spindle.

10. Install the wheel bearing adjusting nut.

11. Adjust the wheel bearing preload. Refer tothe following procedure.


NOTE: To adjust the wheel bearing preload, thebearings must be properly seated and the rollersproperly aligned.

WARNING







!

41

Section 5Assembly

NOTE: If you move the adjusting nut to align thelock plate mounting holes, tighten the nut. Do notloosen or back off the nut.

6. Install the lock plate.

WARNING


7. Install the lock plate mounting screws. Tightenthe mounting screws to 20-30 lb-ft (27-41 N•m).

• The new lock plate mounting screw threadscome equipped with a pre-applied lockingagent.

• If you use the original lock plate mountingscrews, apply two or three drops of Loctite277 or equivalent to the internal threads ofthe ring gear hub.

8. Apply axle grease to the inner face of the sungear thrust washer to help secure the washerto the nut.

9. Install the sun gear thrust washer so that thewasher tangs must engage the slots in thebearing adjusting nut.






!

42

Section 5Assembly



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. If the axle shaft thrust button and/or ring gearthrust buttons are being replaced, apply liquidgasket material to them before pressing intothe spider.

2. Place the planetary spider on a workbenchwith the flange end facing UP. Press the newbuttons into the planetary spider.

3. Inspect the planet pinion bores for damage.Do not reuse pinions with bore surface damage.

4. Apply gear lubricant to the planetary pinionbores and to the pinion shaft journals andshoulder surfaces.

5. Place the planetary spider on a workbenchwith the flange end facing DOWN.

6. Carefully slide the planetary spider over theedge of the workbench just far enough toreach inside to place a planetary pinion andthrust washer.

7. Install the planetary pinion and the inner andouter thrust washers from the large end of theplanetary spider. The thrust washer tangs ofthe thrust washer must engage the slots in theplanetary spider inner and outer supportbosses.

8. Replace the O-ring on each pinion shaft andinsert the pinion shafts. Hand tighten them tothe support journals. The large end of eachpinion shaft must face OUT.

!

9. Press the pinion shafts into the spider untilthe pinion shaft inner shoulders contact thethrust washers.

10. Apply a film of sealant to the outside pinionshaft bores of the planetary spider.

11. Place the planetary spider on a workbenchwith the flange end facing UP.

12. Install the snap rings on each pinion shaft.

13. Install the O-ring at the base of the wheel hubflange.

14. Install the planetary ring gear onto the ringgear hub.




2. Install the slotted head machine screws thattemporarily secure the planetary spider to thewheel hub. Hand tighten the screws. Seat thehead of each screw below the surface of thespider flange.

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


NOTE: The PRC 775P 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 eachfill plughole. Wait and allow the oil to flow throughthe axle. Check the oil level again after a fewminutes and fill to the specified level if necessary.



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

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

43

Section 5Assembly

WARNING


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

2. Clean and inspect the spindle and pistonhousing for damage. Apply a small, twomillimeter bead of Loctite 518 near the OD ofthe spindle flange, on both sides of the spindleflange.

3. Mount the spindle and piston housing (lug onTOP) onto the axle housing using thirteen M20x 2.5 thread capscrews. Tighten the capscrewsin an “X” torquing pattern to achieve 370-480 lb-ft (500-650 N•m) bolt torque. Install10 mm x 60 mm long assembly studs into thefour M8 x 1.25 thread holes in the piston cover.

Wet Disc Brakes

To assemble the PRC 775 W3H wet disc brakes,refer to Maintenance Manual MM-20195, 360 mmWet Disc Brakes. To order this publication, callAxleTech International’s Customer Service Centerat 877-547-3907 or send a fax to 866-547-3987.

NOTE: To continue assembling the PRC 775 W3H wet disc brake wheel end, continue with thefollowing steps.

Wheel End

1. Clean and inspect the piston for damage,inspect the piston grooves to ensure nocontaminants remain in the grooves. Apply oillubricant to the “D” seals and assemble the“D” seals into the appropriate grooves in the piston.

!PRC 775 W3H Wet Disc BrakeWheel End



Spindle and Piston Housing to the Axle Housing

1. Install two temporary studs (M20 x 2.5 threads,approximately four inches long) into the axlehousing flange. Install the studs at the eleveno’clock and one o’clock positions. Figure 5.11.

Figure 5.11

WARNING


NOTE: The piston slightly sticks out of the pistonhousing.

2. Apply an oil film coating on the pistonhousing bores. Use “C” clamps to assemblethe piston over the assembly studs and pushthe piston into the piston housing until itbottoms out.

3. Remove and store the four assembly studs.

4. Install washers and springs on the fourshoulder bolts.

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

6. Clean and inspect the brake housing,stationary plates and dowels for damage.

NOTE: The brake housing has TOP identified witha raised lug.

7. Place the brake housing on an assemblybench. Assemble the eight dowels into theslots in the brake housing.

CAUTION



8. Line up all the friction disc splines andgrooves in a stack so that they can beassembled this way inside the brake housing.

9. Place a friction disc inside the brake housing.Place a stationary disc into the brake housingwhile engaging all the dowels in the disc’sslots.

!

! 10. Repeat these steps until completing theassembly stack of discs. Realign all thefriction disc splines and grooves.

WARNING


11. Apply a small, continuous two millimeterbead of Loctite 518 onto the mounting face ofthe brake housing. Carefully lift the brakehousing assembly (lug on TOP) and install itonto the piston housing that is alreadymounted on the axle.

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

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

13. Install half of the face seal into the brakehousing by using a Caterpillar assembly toolto properly position the O-ring and steel ringassembly beyond the lip and into the taperedbore in the brake housing.

14. Clean and inspect the hub.

15. Install inner and outer bearing cups into thehub. Install the inner bearing cone andspindle seal into the hub. Press the spindleseal flush with the shoulder in the hub bore.



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

17. Install the second half of the face seal into thehub and cup assembly by using a Caterpillarassembly tool to properly position the O-ringand steel ring assembly beyond the lip andinto the tapered bore in the hub.

!

44

Section 5Assembly

18. Measure height of metal face above housingto ensure tolerance is within 1 mm variation.

CAUTION

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

19. Apply a light coating of lubricant to the twomating surfaces of the face seal’s steel ringsonly. Do not allow lubricant to contact the O-ring. Use the same lubricant that was usedon the coolant side.

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

21. Install the outer bearing cone on the ring gearhub. Install the spindle nut on the spindle.Rotate the hub while tightening the nut asdescribed in wheel bearing adjustmentprocedure.

22. Perform the pressure test.


NOTE: To adjust the wheel bearing preload, thebearings must be properly seated and the rollersproperly aligned.

WARNING


1. Install the wheel bearing adjusting nut. Tightenthe nut to 400 lb-ft (542 N•m).





!

!

45

Section 5Assembly

NOTE: If you move the adjusting nut to align thelock plate mounting holes, tighten the nut. Do notloosen or back off the nut.

6. Install the lock plate.

WARNING


7. Install the lock plate mounting screws. Tightenthe mounting screws to 20-30 lb-ft (27-41 N•m).

• The new lock plate mounting screw threadscome equipped with a pre-applied lockingagent.

• If you use the original lock plate mountingscrews, apply two or three drops of Loctite277 or equivalent to the internal threads ofthe ring gear hub.

8. Apply axle grease to the inner face of the sungear thrust washer to help secure the washerto the nut.

9. Install the sun gear thrust washer so that thewasher tangs must engage the slots in thebearing adjusting nut.





• The thrust washer tangs must be properlyinstalled in the bearing adjusting nut slots.

!

10. Apply a film of sealant to the outside pinionshaft bores of the planetary spider.

11. Place the planetary spider on a workbenchwith the flange end facing UP.

12. Install the snap rings on each pinion shaft.

WARNING


13. Install the O-ring at the base of the wheel hubflange.

14. Install the planetary ring gear onto the ringgear hub.




2. Install the slotted head machine screws thattemporarily secure the planetary spider to thewheel hub. Hand tighten the screws. Seat thehead of each screw below the surface of thespider flange.

!

46

Section 5Assembly



1. If the axle shaft thrust button and/or ring gearthrust buttons are being replaced, apply liquidgasket material to them before pressing intothe spider.

2. Place the planetary spider on a workbench withthe flange end facing UP. Press the newbuttons into the planetary spider.

3. Inspect the planet pinion bores for damage. Donot reuse pinions with bore surface damage.

4. Apply gear lubricant to the planetary pinionbores and to the pinion shaft journals andshoulder surfaces.

5. Place the planetary spider on a workbench withthe flange end facing DOWN.

6. Carefully slide the planetary spider over theedge of the workbench just far enough to reachinside to place a planetary pinion and thrustwasher.

7. Install the planetary pinion and the inner andouter thrust washers from the large end of theplanetary spider. The thrust washer tangs ofthe thrust washer must engage the slots in theplanetary spider inner and outer supportbosses.

8. Replace the O-ring on each pinion shaft andinsert the pinion shafts. Hand tighten them tothe support journals. The large end of eachpinion shaft must face OUT.

9. Press the pinion shafts into the spider until thepinion shaft inner shoulders contact the thrustwashers.


NOTE: The PRC 775 axle has a common oil levelbetween the carrier and the wheel ends. The wetdisc brakes must also be filled separately. Fivelocations must be filled. The vehicle must be on alevel surface when filling. Fill to the bottom ofeach fill plughole. Wait and allow the oil to flowthrough the axle. Check the oil level again after afew minutes and fill to the specified level ifnecessary.



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

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

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 oilexits the lower plug (above the 3 or 9 o’clockposition).

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

NOTE: Brake coolant inlet is connected to the0.875"-14 UNF O-ring plug at the top position ofthe brake 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.

47

Section 5Assembly

48

Section 6Specifications

PRC 425 Q Plus™ Wheel End Torque Chart

Item Fastener Torque Value

1 Wheel rim nut Per OEM specification

2 Pinion shaft set screw 35 lb-ft (47 N•m)

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

4 Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification)

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

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

7 Camshaft bracket to spider 85-115 lb-ft (115-156 N•m)

8 Wheel bearing adjusting nut Refer to instructions in Section 3.

1

8

2

3

45

67

49


PRC 425 W3H Wheel End Torque Chart



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


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

5 Pinion shaft setscrew 35 lb-ft (47 N•m)

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

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

16

3

27

5

4

50


PRC 775P Wheel End Torque Chart



2 Lock plate screw 20-30 lb-ft (27-41 N•m)


4 Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification)

5 Camshaft bracket to spider 85-115 lb-ft (115-156 N•m)

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

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

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

7

1

2

3

8

4

5

6

51


PRC 775 W3H Wheel End Torque Chart



2 Lock plate screw 20-30 lb-ft (27-41 N•m)


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

3

6

7

5

52


Lubrication Specification

NOTE: Do not fill only through the axle housingbowl. For axles with a common level, fill the axleat each wheel end and the axle housing bowl tothe bottom of the fill/level plug hole with thespecified oil. Wait and allow the oil to flowthrough the axle. Check the oil level again and fillto the specified level if necessary.

Lubrication Schedule

Operation Off-Highway➀

Initial Oil Change 250 operating hours➀

Check Oil Level 250 operating hours➀

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

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

➀ The interval depends on the individual operating conditions, speeds and loads. Severe operating conditions mayrequire more frequent intervals.

Lubrication Specifications

Outside TemperatureMilitary

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 MIL-PRF-2105-E 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

NOTE: Refer to AxleTech Maintenance Manual 1,Lubrication, for further lubrication information.To order this publication, call AxleTechInternational’s Customer Service Center at 877-547-3907 or send a fax to 866-547-3987.

Specification Oil Description

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


53

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.

CAUTION

The 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 Intervals

Break-In Interval: Change the fluid in the brake housing after the first month or the first 200-250 hours ofoperation, whichever comes first.

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

Hydraulic Fluid Specifications

Use only the brake hydraulic fluid specified by the manufacturer of the vehicle. Do not use different hydraulic fluids. The wrongfluid will damage the seals on the piston.

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