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

General Assembly Instructions
x
Fasteners
When installing fasteners without pre-applied adhesive,
Loctite 243 Blue Threadlocker must be used unless other-
wise stated.
NOTE: Do not apply adhesives or sealants to fasteners
with pre-applied adhesive, or to fastener holes.
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:
•If the removal of a capscrew becomes difficult due
to a worn head or unusually high breakaway torque,
the locking strength can be reduced by heating the
threaded area to approximately 300°F (150°C). Heat
slowly to avoid thermal stresses on the differential
case and gears.
•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.
•Replace any fastener if corners of the head are worn.
•Replace washers if damaged.
•Clean and repair threads of fasteners and holes.
Use a die or tap of the correct size or a fine file for
this purpose.
!CAUTION
THREADS MUST BE WITHOUT DAMAGE AND CLEAN SO
THAT ACCURATE ADJUSTMENT AND CORRECT TORQUE
VALUES CAN BE APPLIED TO FASTENERS AND PARTS.
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.
Tapered Ball Joint Removal
Carriage ball joints use a tapered attachment fit to their
mating component. Often, it is not practical to procure
a special tool to split the taper and separate the com-
ponents. AxleTech Service recommends that ball joint
tapered joints housed within steel or ductile iron com-
ponents can be split using a “shock method”. The shock
method involves impacting the component, with a steel
hammer, close to the tapered location. (DO NOT directly
impact the ball joint or stud directly.) This action tends to
“shock” the tapered joint loose and is a common practice
by AxleTech Service.

Introduction
1
Introduction
Description
This maintenance manual is intended to cover the recommended disassembly/assembly procedures of the AxleTech plane-
tary steering axles steer knuckle/king pin designs.
The steer knuckles on a particular axle model will vary dependent on the wheel brake and tie rod design selected by the
OEM specification; but, service of the steer knuckle/king pin assembly is very similar. Axle shaft designs may also vary by
specific OEM requirements in some axle models. There are two basic king pin designs which are covered by this manual: the
sealed and non-sealed king pin designs, as shown in the illustrations below.
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.
KING PIN
PLUG
SPINDLE
OIL SEAL
ALTERNATE CONSTRUCTION
TYP–TOP AND BOTTOM KING PIN
LOWER KING
PIN CAP
THRUST
WASHER
AXLE HOUSING
OIL SEAL
AXLE HOUSING
BUSHING
STEERING
AXLE SHAFT
AXLE
HOUSING
SHIMS
KNUCKLE
UPPER KING
PIN CAP
KING PIN
CAPSCREW
KING PIN
WASHER
GREASE
FITTING
KING PIN
GREASE
FITTING
SPINDLE
NON-SEALED
DESIGN
SPINDLE
BUSHING
KING PIN
GREASE SEAL
KING PIN
GREASE SEAL
SEALED
DESIGN

Introduction
2
Axle Designs Covered in This Manual
The following knuckle and king pin designs are covered in
this manual.
•Non-sealed king pin
•Sealed king pin with grease seal on king pin
•Sealed king pin with grease seal in knuckle bore
•Inclined king pin with grease seal on king pin
For planetary components, wheel hub, brake components,
and spindle service procedures, refer to the appropriate
planetary axle wheel end service manual. To obtain these
publications, refer to the Service Notes section in this
manual.
Axle Designs Not Covered in This
Manual
•Split knuckle
•Tapered bearing king pin
Identification Tag
All products are identified by the model and serial num-
ber. 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
CUST No.
SERIAL No.
RATIO DATE
Model Nomenclature
P S C 1 7 6 4 HDB 200
Exact
Specification
R = Rigid
S = Steering
= Planetary
= Non-Drive
Last Digit — Carrier
Designation for
Base Model Number
First Two or Three Digits
Wheel-End Designation
(Basic Model Number)
Housing Type Designation
C = Integral Cast
S = Fabricated
Only If Applicable:
T = Transmission on Carrier
O = Oscillating or Pin Mount
L = Mounting Other Than Pad
With Drilling
Brake Type:
DLH — 17 in. (432 mm) Hydraulic Drum — (Dual
Leading Hydraulic)
H — Hydraulic Drum
HDB — Hydraulic Dry Disc
M — Mechanical Drum
N — None
NR — With Rotor Less Calipers
P — CamMaster® “P” Series Cam
RDA — StopMaster® Wedge (Dual Air Chamber)
RDH — StopMaster® Wedge (Dual Hydraulic Cylinders)
RSA — StopMaster® Wedge Single Air Chamber
RSH — StopMaster® Wedge (Single Hydraulic Cylinders)
P
N
Examples:
PSS 166 N 103
PSC 826 RSA 203
PSC 5494 HDB 210

Introduction
3
Exploded Views
ALTERNATE STEERING ARM
15
8
7
55
2
4
7
5
6
13
6
9
14
13
12
11
10
16
Item Description Item Description
1 King Pin Bushing 9 Steer Knuckle
2 Upper King Pin Cap 10 Steer Knuckle Stop Screw
3 Upper King Pin Cap with Integral Steer Arm 11 Steer Knuckle Stop Screw Lock Nut
4 Upper King Pin Cap Capscrew (Long) 12 Lower King Pin Cap Thrust Washer or Grease Seal
5 Upper King Pin Cap Capscrew (Short) 13 Lower King Pin Cap Shims
6 Upper King Pin Cap Capscrew Washer 14 Lower King Pin Cap
7 Upper King Pin Cap Grease Fitting 15 Steer Axle Shaft - Constant Velocity Style
8 Upper King Pin Cap Shims 16 Steer Knuckle Tie Rod Clevis Bushing

Introduction
4
NON-SEALED KING PIN DESIGN SHOWN
14
4
2
1
5
67
9
10 14
11
12
15
13
8
2
3
Item Description Item Description
1 Upper King Pin Cap 9 Lower King Pin Cap Thrust Washer or Grease Seal
2 Upper King Pin Cap Capscrew (Long) 10 Lower King Pin Cap Shims
3 Upper King Pin Cap Capscrew (Short) 11 Lower King Pin Cap
4 Upper King Pin Cap Grease Fitting 12 Lower King Pin Cap Capscrew
5 Upper King Pin Cap Shims 13 Steer Axle Shaft - Cardan Style (Typical)
6 Steer Knuckle 14 Steer Knuckle Tie Rod Assembly with Clevis Ends
7 Steer Knuckle Stop Screw 15 Steer Knuckle Tie Rod with Ball Stud Ends
8 Steer Knuckle Stop Screw Lock Nut

Removal and Disassembly
5
Removal and Disassembly
!WARNING
TO PREVENT SERIOUS EYE INJURY, ALWAYS WEAR EYE
PROTECTION WHEN PERFORMING VEHICLE MAINTE-
NANCE OR SERVICE.
PARK THE VEHICLE ON A LEVEL SURFACE. BLOCK THE
WHEELS TO PREVENT THE VEHICLE FROM MOVING.
SUPPORT THE VEHICLE WITH SAFETY STANDS. NEVER
WORK UNDER A VEHICLE SUPPORTED ONLY BY JACKS.
JACKS CAN SLIP AND FALL OVER. SERIOUS PERSONAL
INJURY AND DAMAGE TO COMPONENTS CAN RESULT.
USE A BRASS OR LEATHER MALLET FOR ASSEMBLY
AND DISASSEMBLY PROCEDURES. NEVER STRIKE
STEEL PARTS WITH A STEEL HAMMER. PIECES OF A
PART CAN BREAK OFF AND CAUSE SERIOUS PERSONAL
INJURY.
Steer Knuckle Removal
1. Remove the hydraulic powering steer cylinder from the
knuckle.
2. Remove the tie rod assembly from the knuckle.
For tie rods with ball stud ends:
It may be necessary to use a brass or plastic mallet to
strike the knuckle arm to loosen the tapered ball stud.
Drive the ball stud out of the knuckle. DO NOT damage
the threads.
3. Remove other components interfering with knuckle
removal.
4. Mark the upper right, lower right, upper left, and lower
left king pin caps to ensure they will be installed in
their original location during axle assembly.
5. Remove the capscrews and washers from the lower
king pin cap. Use two 0.5-13 UNC, 2B thread, grade
8 capscrews in the king pin cap puller holes to remove
the king pin cap. The king pin cap must be removed
squarely to avoid binding in the knuckle bore.
6. Remove the lower king pin cap shim pack and keep it
with the king pin cap.
If the shims are damaged and must be replaced:
Measure the original shim pack thickness. Use the
same shim pack thickness with new shims for initial
assembly.
7. Remove the capscrews and washers from the upper
king pin cap. Use two 0.5-13 UNC, 2B thread, grade
8 capscrews in the king pin cap puller holes to remove
the king pin cap. The king pin cap must be removed
squarely to avoid binding in the knuckle bore.
8. Remove the upper king pin cap shim pack and keep it
with the king pin cap.
If the shims are damaged and must be replaced:
Measure the original shim pack thickness. Use the
same shim pack thickness with new shims for initial
assembly.

Removal and Disassembly
6
9. Remove the king pin cap thrust washer and grease
seals.
•For non-sealed king pin bushing:
Usually the thrust washer will come out of the steer
knuckle with the lower king pin cap. Remove the
thrust washer from the cap. Inspect the washer and
cap thrust surfaces for wear or damage.
NON-SEALED KING PIN BUSHING DESIGN
THRUST
WASHER
LOWER KING PIN CAP
STEER
KNUCKLE
TOP
•For sealed king pin bushing with seal piloted on
king pin cap:
The grease seals will remain on the king pin caps
when removing the caps from the knuckle. Remove
and discard the grease seals if they are worn or
damaged.
SEALED KING PIN BUSHING DESIGN
GREASE
SEAL
LOWER KING PIN CAP
STEER
KNUCKLE
TOP
GREASE
SEAL
•For sealed king pin bushing with seal piloted in
knuckle:
The grease seals will remain in the knuckle bore
when removing the king pin caps. Remove the
grease seals from the knuckle after removing the
knuckle from the axle housing. Discard the grease
seals.
!WARNING
TO AVOID SERIOUS PERSONAL INJURY AND POSSIBLE
DAMAGE TO COMPONENTS, BE VERY CAREFUL WHEN
USING LIFTING DEVICES DURING SERVICE AND MAIN-
TENANCE PROCEDURES.
•Inspect to make sure lifting straps are not damaged.
•Never subject lifting straps to any shock or drop
loading.
10. Use a lifting device to remove the planetary steer
knuckle from the axle housing assembly.
11. Remove the knuckle from the axle housing.
Axle Shaft Assembly Removal
Remove the axle shaft and u-joint assembly from the axle
housing.
Use care to avoid damage to the axle housing oil seal.
For planetary gearing, wheel hub, brake components,
and spindle removal procedures, refer to the appropriate
planetary wheel end service manual.

Removal and Disassembly
7
14
3
3
4
5
67
8
9
2
1
12 13
11
10
Item Description Item Description
1 Planetary Spider 8 Steer Knuckle Tie Rod Nut Cotter Pin
2 Wheel Hub 9 Steer Knuckle Tie Rod Assembly with Ball Stud
Ends
3 Upper King Pin Capscrews (4) 10 Lower King Pin Cap Thrust Washer or Grease
Seal
4 Upper King Pin Cap 11 Lower King Pin Cap Shims
5 Upper King Pin Cap Shims 12 Lower King Pin Cap Capscrews (4)
6 Steer Knuckle 13 Lower King Pin Cap
7 Steer Knuckle Tie Rod Assembly Nut 14 Axle Housing

Removal and Disassembly
8
King Pin Bushing Inspection
Inspect the king pin bushings in the axle housing.
•If the king pin bushings are worn or damaged:
Use one of the following procedures to remove the
bushings.
•If the king pin bushings are not worn or damaged:
Proceed to “Axle Shaft Oil Seal and Bushing” on
page 9.
Non-Sealed King Pin Bushings
1. Grind off the tack welds holding the expansion plug in
the housing bore.
BUSHING
EXPANSION
PLUG
NON-SEALED DESIGN
2. Use a drift that fits through the king pin bushing to
remove the expansion plug by driving it TOWARD the
center of the trunnion.
3. Use a sleeve slightly smaller than the housing bore to
remove the king pin bushing by driving it TOWARD the
outside of the trunnion.
4. Use an emery cloth to clean the housing bores and
remove burrs.
Sealed King Pin Bushings
1. Use a sleeve slightly smaller than the housing bore to
remove the bushing by driving it TOWARD the outside
of the trunnion.
SEALED DESIGN
FLANGED
BUSHING
2. Use an emery cloth to clean the housing bores and
remove burrs.

Disassembly
9
Axle Shaft Oil Seal and Bushing
1. Note the position of the axle shaft oil seal in the
housing bore. The oil seal may be installed with the
outer face flush with the machined counterbore or it
may be pressed further into the housing bore. Should
the oil seal be installed into machined bore, record
oil seal installation depth “X” for later reinstallation of
new oil seal assembly.
NOTE:
A new oil seal must be installed in the housing bore at
the same depth as the original factory installation.
SEAL FLUSH
WITH COUNTERBORE
FACE
COUNTERBORE
FACE
2. Remove the axle shaft oil seal from the housing. DO
NOT damage the housing bore. A damaged bore can
allow oil leakage past the outside diameter of a new
seal.
SEAL PRESSED
DEEP INTO BORE
AXLE
SHAFT
BUSHING
AXLE
SHAFT
OIL SEAL
3. Inspect the axle shaft bushing. Remove the bushing
from the axle housing if it is worn or damaged.
Disassembly
Steering Universal Joint
NOTES:
•NEVER disassemble Permalube universal joints.
Disassembly will void the AxleTech warranty. This style
has no grease fitting on the center parts assembly.
•AxleTech planetary steer axles have three universal
joint designs:
•Wing bearing yokes
•Round bearing yokes or cardan joint
•Constant velocity joints
Wing Bearing Yokes
1. Remove the four cross assembly capscrews from each
yoke.
2. Inspect the cross assembly.
If the cross assembly requires service:
Replace it with a new assembly. DO NOT disassemble
the cross assembly.