AxleTech TA277 User manual

Trans Axles
ASM-0277E
SERVICE MANUAL
October 2018
TA277

Table of Contents
i
Table of Contents
Service Notes ...................................................ii
Asbestos and Non-Asbestos Fibers Warning ......iii
Service Precautions.......................................... v
General Assembly Instructions ........................ vii
Tapered Roller Bearings ................................. vii
Castings ........................................................ vii
Gears............................................................. vii
Seals ............................................................. vii
Fasteners...................................................... viii
Mounting Surfaces........................................ viii
Introduction .................................................... 1
Operation.........................................................1
Technical Specifications...................................1
Identification Tag .............................................2
Model Nomenclature........................................2
Maintenance & Inspection ...............................3
Lubrication...................................................... 3
Lubricant Type..................................................3
Lubricant Capacity ...........................................3
Lubricant Intervals ...........................................3
Checking Carrier Oil .........................................4
Draining Carrier................................................4
Filling Carrier ...................................................5
Checking Gearbox Oil .......................................5
Draining Gearbox .............................................6
Filling Gearbox.................................................6
Illustrations .................................................... 7
Top View...........................................................7
Front View ........................................................7
Rear View.........................................................8
Housing .......................................................... 9
Exploded View..................................................9
Disassembly ................................................. 12
Gearbox Assembly.......................................... 13
Exploded View............................................... 13
Disassembly ................................................. 15
Assembly ...................................................... 17
Axle Sub-Assemblies...................................... 19
Exploded View............................................... 19
Disassembly ................................................. 21
Assembly ...................................................... 23
Brake Assembly ............................................. 25
Exploded View............................................... 25
Disassembly ................................................. 27
Pad Removal................................................. 28
Caliper Overhaul ........................................... 29
Caliper Assembly .......................................... 30
Pad Installation............................................. 31
Assembly ...................................................... 32
Disc Brake Assembly...................................... 33
Exploded View............................................... 33
Disassembly ................................................. 35
Assembly ...................................................... 36
Hub Assembly................................................ 37
Exploded View............................................... 37
Disassembly ................................................. 39
Assembly ...................................................... 40
Differential Assembly..................................... 41
Exploded View............................................... 41
Disassembly ................................................. 43
Assembly ...................................................... 45
Housing ........................................................ 47
Assembly ...................................................... 47
Appendix....................................................... 48
Torque Specifications.................................... 48
Tools ............................................................. 50

Service Notes
ii
Service Notes
This service manual describes the service and repair
procedures for the TA277 Double-Reduction Rigid Drive
Axle. The information contained in this manual is current
at the time of publication and is subject to change without
notice or liability.
Follow all company procedures when you service or repair
equipment or components. Understand all instructions
before performing any product service. Some procedures
require the use of special tools for safe and correct ser-
vice. Failure to use special tools when required can cause
serious personal injury to service personnel, as well as,
damage to equipment and components.
The instructions contained in this service manual are
intended for use by skilled and experienced mechanics
knowledgeable in the installation, repair, and replacement
of the AxleTech product described herein.
!DANGER
Installation, maintenance, and replacement of such prod-
ucts requires a high degree of skill and experience. The
consequences of improper installation, maintenance, or
replacement (including the use of inferior or substandard
components) are grave and can result in product failure
and resulting loss of control of the vehicle, possible injury
or death of persons, and/or possible future or additional
product damage.
AxleTech does not authorize anyone, other than highly
skilled and experienced individuals, to attempt to utilize
the instructions contained in this manual for the installa-
tion, maintenance, or replacement of the product de-
scribed herein, and AxleTech shall have no liability of any
kind for damages arising out of (or in connection with) any
other use of the information contained in this manual.
Updates
For the latest version of this manual, please visit the
AxleTech web site at www.axletech.com. AxleTech
Customer Service can be reached at 800-540-2794
or via email at [e-mail].
Notations
AxleTech International uses the following notation to
warn the user of possible safety problems and to provide
information that will prevent damage to equipment and
components:
!DANGER
A DANGER indicates a procedure that you must follow
exactly or it will cause death or serious injury.
!WARNING
A WARNING indicates a procedure that you must follow
exactly or it may cause death or serious injury.
!CAUTION
A CAUTION indicates a procedure that you must follow
exactly to avoid damaging equipment or components.
NOTE
A NOTE indicates an operation, procedure, or instruction
that is important for proper service. A NOTE can also
supply information that will help to make service quicker
and easier.

Asbestos and Non-Asbestos Fibers Warning
iii
Asbestos and Non-Asbestos Fibers Warning
OSHA*Toxic and Hazardous Substances 29 CFR 1910.1001
Work practices and engineering controls for automotive brake and clutch inspection,
disassembly, repair and assembly -- Mandatory
This mandatory appendix specifies engineering controls
and work practices that must be implemented by the
employer during automotive brake and clutch inspection,
disassembly, repair, and assembly operations.
Proper use of these engineering controls and work
practices by trained employees will reduce employees’
asbestos exposure below the permissible exposure level
during clutch and brake inspection, disassembly, repair,
and assembly operations. The employer shall institute
engineering controls and work practices using either the
method set forth in paragraph [A] or paragraph [B] of this
appendix, or any other method which the employer can
demonstrate to be equivalent in terms of reducing employ-
ee exposure to asbestos as defined and which meets the
requirements described in paragraph [C] of this appendix,
for those facilities in which no more than 5 pairs of brakes
or 5 clutches are inspected, disassembled, reassembled
and/or repaired per week, the method set forth in para-
graph [D] of this appendix may be used:
[A] Negative Pressure Enclosure/HEPA Vacuum System
Method
(1) The brake and clutch inspection, disassembly, repair,
and assembly operations shall be enclosed to cover and
contain the clutch or brake assembly and to prevent the
release of asbestos fibers into the worker’s breathing
zone.
(2) The enclosure shall be sealed tightly and thoroughly in-
spected for leaks before work begins on brake and clutch
inspection, disassembly, repair, and assembly.
(3) The enclosure shall be such that the worker can clearly
see the operation and shall provide impermeable sleeves
through which the worker can handle the brake and clutch
inspection, disassembly, repair and assembly. The integri-
ty of the sleeves and ports shall be examined before work
begins.
(4) A HEPA-filtered vacuum shall be employed to maintain
the enclosure under negative pressure throughout the op-
eration. Compressed-air may be used to remove asbestos
fibers or particles from the enclosure.
(5) The HEPA vacuum shall be used first to loosen the as-
bestos containing residue from the brake and clutch parts
and then to evacuate the loosened asbestos containing
material from the enclosure and capture the material in
the vacuum filter.
(6) The vacuum’s filter, when full, shall be first wetted with
a fine mist of water, then removed and placed immedi-
ately in an impermeable container, labeled according to
paragraph (j)(5) of this section and disposed of according
to paragraph (k) of this section.
(7) Any spills or releases of asbestos containing waste
material from inside of the enclosure or vacuum hose or
vacuum filter shall be immediately cleaned up and dis-
posed of according to paragraph (k) of this section.
[B] Low Pressure/Wet Cleaning Method
(1) A catch basin shall be placed under the brake assem-
bly, positioned to avoid splashes and spills.
(2) The reservoir shall contain water containing an organic
solvent or wetting agent. The flow of liquid shall be con-
trolled such that the brake assembly is gently flooded to
prevent the asbestos-containing brake dust from becom-
ing airborne.
(3) The aqueous solution shall be allowed to flow between
the brake drum and brake support before the drum is
removed.
(4) After removing the brake drum, the wheel hub and
back of the brake assembly shall be thoroughly wetted to
suppress dust.

Asbestos and Non-Asbestos Fibers Warning
iv
(5) The brake support plate, brake shoes and brake com-
ponents used to attach the brake shoes shall be thor-
oughly washed before removing the old shoes.
(6) In systems using filters, the filters, when full, shall be
first wetted with a fine mist of water, then removed and
placed immediately in an impermeable container, labeled
according to paragraph (j)(4) of this section and disposed
of according to paragraph (k) of this section.
(7) Any spills of asbestos-containing aqueous solution or
any asbestos-containing waste material shall be cleaned
up immediately and disposed of according to paragraph
(k) of this section.
(8) The use of dry brushing during low pressure/wet clean-
ing operations is prohibited.
[C] Equivalent Methods
An equivalent method is one which has sufficient written
detail so that it can be reproduced and has been demon-
strated that the exposures resulting from the equivalent
method are equal to or less than the exposures which
would result from the use of the method described in
paragraph [A] of CFR 1910.1001. For purposes of making
this comparison, the employer shall assume that expo-
sures resulting from the use of the method described in
paragraph [A] of this appendix shall not exceed 0.016 f/
cc, as measured by the OSHA reference method and as
averaged over at least 18 personal samples.
[D] Wet Method
(1) A spray bottle, hose nozzle, or other implement capa-
ble of delivering a fine mist of water or amended water or
other delivery system capable of delivering water at low
pressure, shall be used to first thoroughly wet the brake
and clutch parts. Brake and clutch components shall then
be wiped clean with a cloth. Any wastewater generated
must be captured and properly disposed of without allow-
ing it to dry on any surfaces.
(2) The cloth shall be placed in an impermeable container,
labeled according to paragraph (j)(4) of the standard and
then properly disposed of as an asbestos waste, or the
cloth shall be laundered in a way to prevent the release of
asbestos fibers in excess of 0.1 fiber per cubic centimeter
of air.
(3) Any spills of solvent or any asbestos containing waste
material shall be cleaned up immediately according to
paragraph (k) of this section.
(4) The use of dry brushing during the wet method opera-
tions is prohibited.
[59 FR 40964, Aug. 10, 1994; 60 FR 33972, June 29,
1995; 77 FR 17778, March 26, 2012]
For more information, visit www.osha.gov, or call OSHA at
1-800-321-OSHA(6742), TTY 1-877-889-5627.
*References to OSHA, NIOSH, MSHA, and EPA, which
are regulatory agencies in the United States, are made to
provide further guidance to employers and workers em-
ployed within the United States. Employers and workers
employed outside of the United States should consult the
regulations that apply to them for further guidance.

Service Precautions
v
Service Precautions
!DANGER
•ALWAYS WEAR PROPER EYE PROTECTION AND OTH-
ER REQUIRED PERSONAL PROTECTIVE EQUIPMENT
TO PREVENT PERSONAL INJURY WHEN PERFORM-
ING VEHICLE SERVICE.
•WORK IN A WELL-VENTILATED AREA.
•NEVER USE GASOLINE, OR SOLVENTS CONTAINING
GASOLINE. GASOLINE CAN EXPLODE.
•DO NOT USE HOT SOLUTION TANKS OR WATER AND
ALKALINE SOLUTIONS TO CLEAN GROUND OR POL-
ISHED PARTS. DOING SO WILL CAUSE DAMAGE TO
THE PARTS.
•USE HOT SOLUTION TANKS OR ALKALINE SOLU-
TIONS CORRECTLY. READ THE MANUFACTURER’S
INSTRUCTIONS BEFORE USING HOT SOLUTION
TANKS AND ALKALINE SOLUTIONS. THEN CAREFUL-
LY FOLLOW THE INSTRUCTIONS.
•SOLVENT CLEANERS CAN BE FLAMMABLE, POISON-
OUS, AND CAUSE BURNS. EXAMPLES OF SOLVENT
CLEANERS ARE CARBON TETRACHLORIDE, EMUL-
SION-TYPE, AND PETROLEUM-BASED CLEANERS.
READ THE MANUFACTURER’S INSTRUCTIONS
BEFORE USING A SOLVENT CLEANER, THEN CARE-
FULLY FOLLOW THE INSTRUCTIONS. ALSO FOLLOW
THE PROCEDURES BELOW.
•PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK
THE WHEELS TO HELP PREVENT THE VEHICLE FROM
MOVING. NEVER WORK UNDER A RAISED VEHICLE
SUPPORTED BY ONLY A FLOOR JACK. ALWAYS SUP-
PORT A RAISED VEHICLE WITH SAFETY STANDS.
CHOCK THE WHEELS AND MAKE SURE THE UNIT
WILL NOT ROLL BEFORE RELEASING BRAKES. A
JACK CAN SLIP OR FALL OVER. SERIOUS PERSONAL
INJURY CAN RESULT.
•IMPROPER JACKING AND SUPPORT METHODS CAN
CAUSE STRUCTURAL DAMAGE THAT RESULTS IN
LOSS OF VEHICLE CONTROL, SEVERE PERSONAL
INJURY OR DEATH. REFER TO THE VEHICLE MANU-
FACTURER FOR PROPER JACKING AND SUPPORT
METHODS.
!WARNING
FOLLOW THE SPECIFIED PROCEDURES IN THE INDICAT-
ED ORDER TO AVOID PERSONAL INJURY OR EQUIPMENT
MALFUNCTION/DAMAGE.
BEFORE STARTING A VEHICLE:
•Sit in the driver’s seat
•Place shift lever in neutral
•Set the parking brake
BEFORE WORKING ON A VEHICLE OR LEAVING THE
CAB WITH ENGINE RUNNING:
•Place shift lever in neutral
•Set the parking brake
•Chock the wheels
WHEN PARKING THE VEHICLE OR LEAVING THE CAB:
•Place shift lever in neutral
•Set the parking brake
!CAUTION
•DO NOT RELEASE THE PARKING BRAKE OR AT-
TEMPT TO SELECT A GEAR UNTIL THE AIR PRES-
SURE IS AT THE CORRECT LEVEL.
•TO AVOID DAMAGE TO THE TRANSMISSION DURING
TOWING:
•Place shift lever in neutral
•Lift the drive wheels off of the ground or
disconnect the driveline
•DO NOT OPERATE VEHICLE IF ALTERNATOR LAMP IS
LIT OR IF GAUGES INDICATE LOW VOLTAGE.
Omissions
Every effort has been made to ensure the accuracy of all
information in this manual. However, AxleTech makes no
expressed or implied warranty or representation based on
the enclosed information. Any errors or omissions may be
reported to AxleTech, 1400 Rochester Road, Troy, Michi-
gan, 48083 USA.

Service Precautions
vi
Repair Warnings
!DANGER
USE OF OTHER THAN RECOMMENDED TOOLS, PARTS,
AND INSTRUCTIONS LISTED IN THIS PUBLICATION MAY
PLACE THE SAFETY OF THE SERVICE TECHNICIAN OR
VEHICLE DRIVER IN JEOPARDY.
DO NOT WELD REPAIR, HEAT, BEND OR RECONDITION
AXLE COMPONENTS. THIS WILL REDUCE COMPONENT
STRENGTH, VOID AXLETECH’S WARRANTY, AND CAN
RESULT IN SERIOUS PERSONAL INJURY AND DAMAGE
TO COMPONENTS. ALWAYS REPLACE DAMAGED OR
OUT-OF-SPECIFICATION COMPONENTS.
•When disassembling various assemblies, lay all parts
on a clean bench in the same sequence as removed
to simplify assembly and reduce the possibility of
losing parts.
•Provide a clean work area. Make sure no dirt or foreign
material enter the unit during repair and assembly.
•Disconnect the vehicle’s battery before removing or
installing electronic parts.
•The location of components varies with each OEM.
•The removal and installation procedure described for
each component may vary between vehicles.
•Use a rubber mallet for disassembly and assembly
procedures. NEVER hit steel parts with a steel
hammer. Pieces of a part can break off and cause
serious personal injury.
•Remove nicks, marks, and burrs from parts having
machined or ground surfaces. Use a fine file, India
stone, emery cloth or crocus cloth for this purpose.
Torque Specifications
•Tightening torque specifications indicated in this
manual must be adhered to at all times.
•A tightening torque weaker than indicated may lead to
a shearing stress and may break the bolt.
•A stronger tightening torque may lead to yielding of
the bolt or an increasing risk of cracking.
Damaged Components
•All damaged components must be replaced by new
components.
•Clean and repair the threads of fasteners and holes.
Use a die or tap of the correct size or a fine file for this
purpose.
•Replace any fastener if corners of the head are worn.
•Since the cost of a new part is generally a small
fraction of the total cost of downtime and labor,
avoid reusing a questionable part that could lead to
additional repairs and expense.
•Always use genuine AxleTech replacement parts.
Cleaning
1. Remove gasket material using a gasket scraper taking
care not to damage machined surfaces.
2. Steam clean or pressure wash the assembly after
plugging all breathers and vents.
NOTE: NEVER direct full pressure at any of the seals (input
shaft, wheel hubs, or brakes).
3. Use solvent cleaners or alkaline solutions to clean
all metal parts with rough surfaces. Rinse alkaline
solution off with water after cleaning.
4. Use solvent cleaners and a brush to clean all metal
parts that have ground or polished surfaces.
NOTE: NEVER clean ground or polished surfaces with
water, steam, alkaline solution, or place in a hot tank.
5. Dry all parts after washing using clean rags or paper
towels.
6. Apply a light oil film to all parts to be reused and
reassembled.
7. If parts are being stored after cleaning, apply a
corrosion-preventive material to all machined
surfaces. Store the parts in a special paper or other
material that prevents corrosion.

General Assembly Instructions
vii
General Assembly Instructions
Tapered Roller Bearings
!CAUTION
Dry bearings with clean paper or rags. NEVER use
compressed air, which can cause abrasive particles to
contaminate the bearings. Damage to components and
reduced lining life can result.
If parts are clean and properly lubricated, it is rare for
bearings to be damaged. Proper installation is also criti-
cal to avoid vibration, noise, and reduced bearing life.
Bearings should be removed when:
•Bearing surfaces show abnormal wear
•Bearings are chipped (due to improper cleaning
during assembly, improper lubrication, or a broken
component inside the transfer case)
•Centers of the large diameter end of the rollers are
worn level with or below the surface
•Centers of the large diameter end of the rollers are
worn to a sharp edge
•A roller groove is worn in the cup or cone inner race
surfaces visible at the small or large diameter ends of
both parts
•Deep cracks or breaks are present in the cup, cone
inner race, or roller surfaces
•Bright wear marks are present on the outer surface of
the roller cage
•Etching and pitting is present on the rollers and on
surfaces of the cup and cone inner race that touches
the rollers
•Spalling or flaking is present on the cup and cone
inner race surfaces that touch the rollers
During disassembly:
•Remove bearings with pullers designed for this
purpose to avoid damaging the bearing.
•Carefully wash and re-lubricate all bearings as
removed and protectively wrap until ready for use.
•Store all bearings in a dry and clean area to minimize
the possibility of corrosion, contamination, or other
damage.
During assembly:
•Install bearings in a clean environment, free from
dust, debris, moisture, and other contaminants.
•Machining, filing, soldering, grinding, etc. should
be kept away from the assembly area to prevent
contaminating the bearings.
•Check the cleanliness of the bearing:
•If the bearing is new, unpack it immediately
before assembly.
•Used bearings should be cleaned with petrol or
benzine and then oiled.
•Verify the bore is deburred and cleaned before
installing the bearing. Use 180-grit emery cloth to
remove small imperfections in the metal.
•Bearings are installed the easiest by cooling or
heating (in hot oil to 80°C) instead of using a press.
Do not apply any shock or impact techniques (like
hammering) to install the bearings.
•When a bearing has been heated for assembly, apply
a small amount of grease or oil after assembly.
•When installing on a tight shaft, force is to be applied
to the inner ring only.
Castings
•Inspect for damage or cracking. Replace as required.
NEVER weld to repair the casting.
Gears
•Inspect for pitting or damage. Replace as required.
•Replace beveled gear set, as required, with a matched
set.
Seals
!WARNING
When applying some silicone gasket materials, small
amounts of acid vapor are present. To prevent possible
serious injury, the work area must be well-ventilated.
If the silicone gasket material gets into your eyes,
flush them with water for 15 minutes. Have your eyes
checked by a doctor as soon as possible.
•O-rings: After removal, always replace with new ones.

General Assembly Instructions
viii
•Lipped seals: All disassembled seals shall be rejected
and replaced by a new seal.
•Gaskets: After removal, always install a new gasket.
Apply a 0.125 inch (3.18 mm) diameter continuous
bead of silicone gasket material around one surface.
Also apply the gasket material around the edge of
all the fastener holes on that surface. Assemble
immediately and wait 20 minutes before filling the
assembly with lubricant.
!CAUTION
Too much gasket material can block lubrication pas-
sages. Damage to components can result.
Recommended Lubricant: GRADE NLGI 2
During assembly:
•Verify the seal bearing surface edges are free of burrs
and nicks that may damage seals.
•Lubricate properly:
•Lubricate the entire interior surface of the ring
and primarily the seal lips.
•Pack the space between the lips with grease.
NOTE: Do not use an excessive quantity of
lubricant since liquefaction may occur during
operation and appear outside the housing. This
could easily be mistaken for a leak.
•The ring shall be engaged in its housing
perpendicularly and concentrically to the shaft.
•Do not damage the seal lips and turn them over during
installation.
Fasteners
When installing fasteners without pre-applied adhesive,
Loctite 243 Blue Threadlocker must be used unless other-
wise stated.
Product characteristics:
•Color: Pale blue
•Temperature Resistance:
-67 to 302°F (- 55 to 150°C)
•TO BE USED WITH CARE:
Avoid any contact with eyes and skin.
During disassembly:
•In the event of sticking, heat the screws.
•Clean excess material off all surfaces as thoroughly as
possible.
•Clean and carefully degrease surfaces (any lubricant
prevents setup therefore making the product
ineffective) using a solvent or by washing the parts.
•Let all components dry completely.
During assembly:
•Apply one drop to the threads, preferably at the end of
the screw, of Loctite 243 Blue Threadlocker.
•Assemble the parts and tighten to the required
torque.
•All screws shall be tightened within 5 minutes
following assembly of the parts. The unit can be used
10 minutes after assembling.
NOTE: To reduce setup time, spray Loctite 7649 Locquic
Primer N activator on the threads, allow to evaporate, and
then apply Loctite 243.
Mounting Surfaces
For all mounting surfaces that do not use an o-ring seal,
use Loctite 5699 RTV Silicone Gasket.
Product characteristics:
•Color: Grey
•Adhesive power: Weak, nevertheless, do not use on
centering; only on the faces.
•Temperature Resistance:
-67 to 392°F (-55 to 200°C)
•TO BE USED WITH CARE:
Avoid any contact with eyes and skin.
During disassembly:
•In the event of sticking, tap the parts to break the
Loctite film.
•Remove particles of Loctite as thoroughly as possible.
•Clean and carefully degrease surfaces (any lubricant
prevents setup therefore making the product
ineffective) using a solvent or by washing the parts.
•Let all components dry completely.
During assembly:
•Apply a single bead to one of the mating surfaces well
around the attachment holes.
•Assemble the parts and tighten to the required
torque.
•Leave to dry: Parts can be handled after 30 minutes.
•Total setup time: 18 to 24 hours

Introduction
1
Introduction
Operation
The TA277 is a double-reduction rigid drive axle designed for baggage and cargo tractors with short wheel bases. The TA277
is intended to replace the time-tested TA267 with a modern and elegant design to increase axle life and serviceability.
Featuring a quieter and stronger differential, full-floating axle shafts, and an all-new wheel-end design, the TA277 is the next
generation axle of an industry standard with the intent to raise market expectations by reducing downtime and total cost of
ownership.
When replacing parts, only use factory original parts and parts sets. Parts must be ordered from AxleTech International.
Any damage to parts not described in this manual must be repaired or replaced using original parts.
Technical Specifications
Model TA277
Capacity 6,000 lbs (2,700 kg)
Axle type Full-floating rigid axle
Final ratio 12.33, 14.14, 17.00, 17.57, or 20.00
Housing Ductile iron center section with steel tubes
Wheel mounting Hub piloted 8 stud - 6.50 in (165 mm) bolt circle
with a 4.74 in (120 mm) pilot diameter
Input flange 1310 companion flange or as specified
Brakes Hydraulic disc, single or dual caliper, 13.0 in (330 mm)
Parking brake Optional hand lever, cable-actuated brake at input
Minimum rim size 16 in (406 mm)
Flange to flange 36.1 in (917 mm)
37.8 in (960 mm)
47.6 in (1,210 mm)
51.2 in (1,300 mm)
Typical axle weight 530 lbs (240 kg) for 47.6 in (1,210 mm) flange to flange
Oil Capacity 7 qt (6.62 L)

Introduction
2
Identification Tag
All products are identified by the model and serial number. This information is stamped on the identification tag and affixed
to the case. Have reference numbers handy when ordering replacement parts or requesting service repairs.
DO NOT REMOVE OR DESTROY THE IDENTIFICATION TAG.
Model Nomenclature
TA 277 HDB 208 XXX
Base Model Number
267 - Non-planetary
268 - Planetary Wheel End
277 - Non-planetary
Type
TA - Trans Axle
Specification
Brakes
DSH - Duo Servo Hydraulic
HDB - Hydraulic Disc
NX - None
Carrier Ratio

Lubrication
3
Maintenance & Inspection
To keep a vehicle running properly, it is important to per-
form preventive maintenance on the vehicle components.
This ensures the vehicle and its subassemblies will operate
properly throughout their useful life. To cover preventive
maintenance completely, you must review the following
subjects in detail.
•Inspect the axle:
•Check the oil level - See “Lubrication” on page 3.
•Inspect under the vehicle for loose/missing bolts -
Replace any missing or broken bolts with the proper
part from the Illustrated Parts List. Tighten any loose
bolts to the torque specifications outlined in this
publication.
•Check the axle for lubricant leaks - Any lubricant leak
could cause a catastrophic failure. Check for leaks at
mating surfaces and plugs. Make sure the lubricant
is not being blown back from the engine or another
vehicle component.
•Changing the Lubricant
!WARNING
REMEMBER TO BE CAREFUL WHEN CHANGING
THE LUBRICANT, AS IT MAY BE HOT.
•See “Lubricant Intervals” on page 3.
•Use the correct “Lubricant Type” on page 3.
•Use the proper amount of oil noted in the “Lubricant
Capacity” on page 3.
•Follow the carrier procedures outlined in “Draining
Carrier” on page 4 and “Filling Carrier” on page
5.
•Follow the wheel end procedures outlined in
“Draining Gearbox” on page 6 and “Filling
Gearbox” on page 6.
•Verify the oil is to the proper level as explained in
“Checking Carrier Oil” on page 4 and “Checking
Gearbox Oil” on page 5.
Lubrication
With any product containing gears, lubrication is possibly
the most important component effecting the product life
cycle. It is critical to use the correct lubricant, follow oil
change intervals, and check the oil level regularly.
Lubricant Type
Due to the duty cycles imposed on equipment, a multi-
grade lubricant 80W90 with service level API GL5 and
approved as meeting US MIL-L-2105 D specification is
recommended for the carrier housing and gearbox.
Avoid mixing different oil types, even if from the same
brand name, to avoid compatibility issues that can cause
seal materials to deteriorate.
Failure to use the required lubricant may affect perfor-
mance and warranty coverage.
Lubricant Capacity
Carrier & wheel ends - 5 qts (4.7 L )
Gearbox - 1.25 qts (1.2 L)
Lubricant Intervals
The lubricant intervals vary depending on the type of vehi-
cle, operating duty cycle, and application.
Under normal operating conditions:
Oil Changes: After first 100 hours, then every 500 hours
Oil Level Check: Every 50 hours

Lubrication
4
Checking Carrier Oil
1. Remove the oil fill plug located in the center of the
carrier housing.
Carrier
Oil Drain Plug
Correct
Oil Level
Carrier
Oil Fill Plug
2. Verify oil is at the proper level by confirming it is even
with the bottom of the oil fill plug opening. When the
plug is removed to check the level, oil should actually
seep out. Do not use your finger to feel for the oil. Even
if you can touch the oil, it may not be at the proper
level.
Improper Oil Level
Hole
Proper Oil Level
Hole
3. If the oil level is low, add the recommended oil type
and quantity until it is at the proper level. Filling
should be done slowly to provide enough time to
ensure the oil flows through the complete assembly.
4. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 35 lbs. ft. (48 N·m) minimum.
Draining Carrier
Draining should be done immediately following vehicle
operation when the oil is warm.
1. Place a drain pan underneath the unit.
2. Remove the magnetic oil drain plug.
Carrier
Oil Drain Plug
Correct
Oil Level
Carrier
Oil Fill Plug
3. Drain the oil.
4. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 35 lbs. ft. (48 N·m) minimum.
5. Dispose of oil according to local requirements.
Note: Fine metal particles attached to the magnetic plug
are normal. If larger pieces are found, component damage
has occurred and needs to be repaired.

Lubrication
5
Filling Carrier
1. Ensure the vehicle is parked on a level surface.
2. Remove the oil fill plug located on the front of the
carrier case.
Carrier
Oil Drain Plug
Correct
Oil Level
Carrier
Oil Fill Plug
3. Fill with the recommended oil type and quantity.
Filling should be done slowly to provide enough
time to ensure the oil flows through the complete
assembly.
4. Verify oil is at the proper level when it is even with
the bottom of the oil fill plug opening. See “Checking
Carrier Oil” on page 4.
5. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 35 lbs. ft. (48 N·m) minimum.
Checking Gearbox Oil
1. Remove the oil level plug (see Oil Level location
below).
Gear Box
Oil Drain Plug
Gear Box
Oil Fill Plug
Correct
Oil Level
2. Verify oil is at the proper level by confirming it is even
with the bottom of the oil level opening. When the
plug is removed to check the level, oil should actually
seep out. Do not use your finger to feel for the oil. Even
if you can touch the oil, it may not be at the proper
level.
Improper Oil Level
Hole
Proper Oil Level
Hole
3. If the oil level is low, add the recommended oil type
and quantity until it is at the proper level. Filling
should be done slowly to provide enough time to
ensure the oil flows through the complete assembly.
4. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 20 to 25 lbs. ft. (27-34 N·m).

Lubrication
6
Draining Gearbox
Draining should be done immediately following vehicle
operation when the oil is warm.
1. Place a drain pan underneath the unit.
2. Remove the magnetic oil drain plug.
Gear Box
Oil Drain Plug
Gear Box
Oil Fill Plug
Correct
Oil Level
3. Drain the oil.
4. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 20 to 25 lbs. ft. (27-34 N·m).
5. Dispose of oil according to local requirements.
Filling Gearbox
1. Ensure the vehicle is parked on a level surface.
2. Remove the oil fill plug located on the front of the
gearbox case.
Gear Box
Oil Drain Plug
Gear Box
Oil Fill Plug
Correct
Oil Level
3. Add the recommended oil type and quantity until it is
at the proper level using the Fill Hole (see illustration
above). Filling should be done slowly.
4. Verify oil is at the proper level when it is even with
the bottom of the oil level opening. See “Checking
Gearbox Oil” on page 5.
5. Clean and apply pipe thread sealant to the oil fill plug
and tighten to 20 to 25 lbs. ft. (27-34 N·m).

Illustrations
7
Illustrations
Top View
Short Shaft
Assembly
Long Shaft
Assembly
Carrier
Gear Box
Wheel End
Assembly
1x75 Brake Bleeder
Input Shaft
Front View
Carrier
Oil Drain Plug
Carrier
Oil Fill Plug
Breather
Parking Brake
Assembly

Illustrations
8
Rear View
Gear Box
Oil Drain Plug
Gear Box
Oil Fill Plug

Housing
9
Housing
Exploded View
4
59
10
11
12
11
18
15
13
14
21 619
18
1
2
24
41
40
46
45
44
34
99
98
94
49
43 42
39 37
38 37
92
91 3
45
67
22
23
26
25
43
47
48
49
27
28
29
36
93
57 58
61
83
81
82
76
69
72
75
73
72
71
71
74
97
96
89 62
55
56
57
58
1
2
65
64
84 85
86
88
87
50
51
66
62
89
79
78 77
80
16
17
35
32
33
59
53
95
63
60
54
52
90
70
67
68
8
20
31
30

Housing
10
Item Description Item Description
1 Torque Plate 31 Capscrew
2 Torque Plate 32 OIl Fill Plug
3 Carrier Flange Half & Tube Weldment 33 Capscrew
4 Lock Nut 34 Gearbox Cover
5 Washer 35 Dowel
6 Input Flange 36 Key
7 Oil Seal Assembly 37 Nut
8 Nut 38 Lock Plate
9 Parking Brake Assembly 39 Driven Gear
10 Bushing 40 Nut
11 Washer 41 Washer
12 Capscrew 42 Thrust Washer
13 Capscrew 43 Bearing Cone
14 Spacer 44 Magnetic Oil Drain Plug
15 Caliper Bracket 45 Washer
16 Washer 46 Nut
17 Nut 47 Pinion Cage Assembly
18 Washer 48 Shim Kit
19 Capscrew 49 Bearing Cup
20 Capscrew 50 Bearing
21 Parking Brake Rotor 51 Snap Ring
22 Roll Pin 52 Ring Gear & Pinion Assembly
23 Stud 53 Capscrew
24 Gearbox Case 54 Differential Case - Plain Half
25 Bearing 55 Thrust Washer
26 Input Gear 56 Differential Pinion Gear
27 Bearing 57 Differential Side Gear
28 Snap Ring 58 Thrust Washer
29 Bearing Cap 59 Differential Case - Flange Half
30 Washer 60 Differential Case Assembly

Housing
11
Item Description Item Description
61 Differential Assembly 81 Spacer
62 Bearing Cup 82 Oil Seal Assembly
63 Pin 83 Hub Assembly
64 Thrust Block 84 Nut
65 Magnetic Plug 85 Washer
66 Carrier Plain Half & Tube Weldment 86 Breather Assembly
67 Axle Shaft 87 Coupling
68 Shaft Assembly 88 Nipple
69 Cotter Pin 89 Bearing Cone
70 Sleeve 90 Nut
71 Bearing Cone 91 Washer
72 Bearing Cup 92 Capscrew
73 Bearing Housing 93 Spider
74 Washer 94 Differential Service Kit
75 Capscrew 95 Washer
76 O-ring 96 Plug
77 Wheel Stud 97 Capscrew
78 Wheel Hub 98 Slide Pin
79 Brake Rotor 99 Brake Assembly
80 Nut