AxleTech PSS165 User manual

Planetary Steer Axle
ASM-0910E
SERVICE MANUAL
October 2019
Knuckle Designs
PSS165
PSS166
PSC204
PSC205
PSOC205
PSC353
PSC594
PSC822
PSC824
PSTC824
PSC825
PSC826
PSC1044
PSC1045
PSC1485
PSC1614
PSC1615
PSC1617
PSC1764
PSC1794
PSC1875
PSC1876
PSC4564
PSC4565
PSC5494

Table of Contents
i
Table of Contents
Service Notes ...................................................ii
Asbestos and Non-Asbestos Fibers Warning ......iii
Service Precautions.......................................... v
Towing ............................................................. v
Repair Warnings.............................................. vi
Torque Specifications...................................... vi
Cleaning ......................................................... vi
Damaged Components.................................... vi
Repair Welding............................................... vii
Omissions...................................................... vii
General Assembly Instructions ....................... viii
Tapered Roller Bearings ................................ viii
Castings ....................................................... viii
Gears............................................................ viii
Seals .............................................................. ix
Mounting Surfaces.......................................... ix
Fasteners......................................................... x
Tapered Ball Joint Removal............................... x
Introduction .................................................... 1
Description ......................................................1
Axle Designs Covered in This Manual ................2
Axle Designs Not Covered in This Manual ..........2
Identification Tag .............................................2
Model Nomenclature........................................2
Exploded Views ................................................3
Removal and Disassembly ................................ 5
Steer Knuckle Removal.....................................5
Axle Shaft Assembly Removal...........................6
King Pin Bushing Inspection .............................8
Axle Shaft Oil Seal and Bushing........................9
Disassembly .................................................... 9
Steering Universal Joint....................................9
Wing Bearing Yokes..........................................9
Round Bearing Yokes or Cardan Joint............. 10
Constant Velocity Joint .................................. 11
Preparing Parts for Assembly.......................... 11
Cleaning ....................................................... 11
Parts Inspection............................................ 12
Flush Lubricant From the Axle Housing........... 12
Assembly and Installation .............................. 12
Assembly of Steering Universal Joint.............. 12
Axle Shaft Bushing & Seal Installation........... 14
Installation of King Pin Bushings ................... 15
Assembly of Steer Knuckle ............................ 17
Steer Knuckle Adjustment ............................. 18
Adjust Knuckle Vertical End Play.................... 19
Final King Pin Cap Installation....................... 20
Axle Components .......................................... 21
Axle Shaft & Universal Joint........................... 21
Spindle, Brake, & Planetary Wheel End ......... 21
Torque Specifications .................................... 22
Lubrication Specifications.............................. 23
Appendix....................................................... 24
General Torque Specifications ....................... 24
Torque Values for Fasteners........................... 26

Service Notes
ii
Service Notes
This service manual describes the service and repair pro-
cedures for planetary steer axle knuckles. The information
contained in this manual is current at the time of publica-
tion 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 ser[email protected].
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
OTHER REQUIRED PERSONAL PROTECTIVE
EQUIPMENT TO PREVENT PERSONAL INJURY WHEN
PERFORMING 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
POLISHED PARTS. DOING SO WILL CAUSE DAMAGE
TO THE PARTS.
•USE HOT SOLUTION TANKS OR ALKALINE
SOLUTIONS CORRECTLY. READ THE
MANUFACTURER’S INSTRUCTIONS BEFORE USING
HOT SOLUTION TANKS AND ALKALINE SOLUTIONS.
THEN CAREFULLY FOLLOW THE INSTRUCTIONS.
•SOLVENT CLEANERS CAN BE FLAMMABLE,
POISONOUS, AND CAUSE BURNS. EXAMPLES
OF SOLVENT CLEANERS ARE CARBON
TETRACHLORIDE, EMULSION-TYPE, AND
PETROLEUM-BASED CLEANERS. READ THE
MANUFACTURER’S INSTRUCTIONS BEFORE
USING A SOLVENT CLEANER, THEN CAREFULLY
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 SUPPORT 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
MANUFACTURER 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 the shift lever in neutral
•Set the parking brake
BEFORE WORKING ON A VEHICLE OR LEAVING THE CAB
WITH ENGINE RUNNING:
•Place the shift lever in neutral
•Set the parking brake
•Chock the wheels
WHEN PARKING THE VEHICLE OR LEAVING THE CAB:
•Place the shift lever in neutral
•Set the parking brake
!CAUTION
•DO NOT RELEASE THE PARKING BRAKE OR
ATTEMPT TO SELECT A GEAR UNTIL THE AIR
PRESSURE IS AT THE CORRECT LEVEL.
•TO AVOID DAMAGE TO THE TRANSMISSION DURING
TOWING:
•Place the shift lever in neutral
•Lift the drive wheels off of the ground or
disconnect the driveline
•DO NOT OPERATE VEHICLE IF THE ALTERNATOR
LAMP IS LIT OR IF THE GAUGES INDICATE LOW
VOLTAGE.
Towing
Due to the wide range of environments and applications
for AxleTech axles, it is recommended to follow the towing
instructions from the vehicle Original Equipment Manufac-
turer (OEM).

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.
Cleaning
•Remove gasket material using a gasket scraper taking
care not to damage machined surfaces.
•Steam clean or pressure wash the assembly after
plugging all breathers, vents, and hydraulic inlets.
NOTE: NEVER direct full pressure at any of the seals
(input shaft, wheel hubs, or brakes).
•Use solvent cleaners or alkaline solutions to clean all
metal parts with rough surfaces. Parts must remain
in hot solution tanks until completely cleaned and
heated. Rinse alkaline solution off with water after
cleaning.
•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.
•Dry all parts after washing using clean rags or paper
towels.
•Apply a light oil film to all parts to be reused and
reassembled.
•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.
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.

Service Precautions
vii
Repair Welding
!DANGER
THE HIGH TEMPERATURE CAUSED BY THE OPEN FLAME
FROM A CUTTING TORCH CAN IGNITE THE OIL IN THE
AXLE HOUSING AND CAN CAUSE SERIOUS PERSONAL
INJURY.
In the interest of safety and preserving the service life of
drive axle assemblies, AxleTech recommends that assem-
blies are not repair welded. Repair welding can detract
from the structural integrity of a component, particularly
to heat treated parts where the benefit of heat treatment
may be nullified by welding.
Since it can be extremely hazardous and detrimental to
repair weld components of any kind, repair welding can
be approved only where stringent controls are imposed
and equipment, customarily located at manufacturing
facilities, is employed, so as to minimize the potentially
detrimental effects of repair welding.
Please contact AxleTech if you believe that repair welding
will work for your particular situation.
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.

General Assembly Instructions
viii
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. DAM-
AGE 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 replaced when:
•Bearing surfaces show abnormal wear
•Bearings are chipped (due to improper cleaning
during assembly, improper lubrication, or a broken
component inside the 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.
•Replace thrust washer, differential side gear, and
pinion gear with a new matched set. Do not mix old
and new parts. Damage to components can result.

General Assembly Instructions
ix
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.
Recommended Lubricant: Gear Oil
•O-rings: After removal, always replace with new ones.
•Lipped seals: All disassembled seals shall be
discarded and replaced by a new seal.
•Gaskets: After disassembly, always install a new
paper or silicone gasket.
•Silicone Gaskets - Apply a 0.125” (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.
0.125" (3.18 MM)
DIAMETER
SILICONE GASKET
MATERIAL BEAD
!CAUTION
TOO MUCH GASKET MATERIAL CAN BLOCK LUBRI-
CATION PASSAGES. DAMAGE TO COMPONENTS CAN
RESULT.
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.
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