AxleTech 5000 Series User manual

Independent Suspension
Axle System
5000 Series
Maintenance Manual ISAS5
Issued -201
ISAS5 SEPTEMBER, 2017

i
Service Notes
Before You Begin
This manual provides maintenance and service
proc e dures f o r AxleTech ’s indep enden t
suspension axle system ISAS 5000 Series. The
information contained in this manual was current
at the time of printing and is subject to change
without notice or liability. Before you begin
procedures:
1. Read and understand all instructions and pro-
cedures before you begin to service compo-
nents.
2. Read and observe all Caution and Warning
safety alerts that precede instructions or pro-
cedures you will perform. These alerts help to
avoid damage to components, serious per-
sonal injury, or both.
3. Follow your company’s maintenance and ser-
vice, installation, and diagnostics guidelines.
4. Use special tools when required to help avoid
serious personal injury and damage to com-
ponents.
SafetyAlerts,Torque Symbol and
Notes
WARNING
A Warning alerts you to
an instruction or
procedure that you must
follow exactly to avoid
serious personal injury
and damage to
components.
CAUTION
A Caution alerts you to
an instruction or
procedure that you must
follow exactly to avoid
damage to components
and possible serious
personal injury can also
occur.
The torque symbol alerts
you to tighten fasteners
to a specified torque
value.
NOTE:
A Note provides
information or
suggestions that help you
correctly service a
component.
ISAS5 SEPTEMBER, 2017

i
Table of Contents
Section 1 - Exploded Views
Differential .............................................................................................. 1-1
Suspension..................................................................................... 1-2
Hub Reduction................................................................................ 1-3
Section 2 - Disassembly
Removal of Springs and Shock Absorber............................................. 2-1
Cardan Joint............................................................................................... 2-2
Suspension................................................................................................. 2-2
Brake Disc................................................................................................... 2-3
Differential Halfshaft.......................................................................................2-4
Hub Reduction............................................................................................ 2-5
Section 3 - Inspection
Tapered RollerBearings................................................................................... 3-1
Seals..................................................................................................................3-1
Replacing a WheelStud.................................................................................... 3-1
Fasteners..................................................................................................... 3-1
Section 4 - Assembly
Hub Reduction............................................................................................ 4-1
Differential Halfshaft.......................................................................................4-6
Brake Disc................................................................................................... 4-7
Suspension................................................................................................. 4-7
Cardan Joint.............................................................................................4-11
Shock Absorber.......................................................................................4-11
Section 5 - Lubrication
Oil Change................................................................................................... 5-1
Lubrication.................................................................................................. 5-2
Section 6 - Special Tools
Tool drawings............................................................................................. 6-1
ISAS5 SEPTEMBER, 2017

1-1
Differential
Item
Qty Description
Item
Qty Description
1
1
Axle housing
11
16
Socket head capscrew - M8x1.25x25 (grade 8.8)
2
1
Carrier assembly
12
2
Halfshaft
3
2
Breather
13
2
Brake disc
4
1
Filler plug
14
32
Socket head capscrew - M8x1.0x35 (grade 10.9)
5
1
Drain plug
15
1
Brake assembly
6
2
Lock nut - M48x1.5
16
8
Lock washer
7
2
Lock washer
17
8
Socket head bolt - M20x1.5x45 (grade 10.9)
8
2
Ball bearing SKF 6410
18
4
Straddle bearing
9
2
Bearing retainer and seal housing
19
4
Circlip internal
10
2
Seal NCR 23479
20
8
Hex head capscrew
1 3 4 5
3
10 12 13 17 16
14 15
6 7 8 9 11
2 0 1 9 1 8
2
ISAS5 SEPTEMBER, 2017

1-2
Section 1
Exploded View Suspension
Item
Qty Description
Item
Qty Description
1
1
Lower wishbone
19
2
Straddle bearing
2
2
Bushing
20
2
Internal circlip
3
1
Lower spring mounting
21
4
Hex head capscrew
4
1
Mounting pivot pin
22
1
Bump stop
5
1
Locking strip
23
1
Washer
6
2
Hex head capscrew - M6x1.0x20 (grade 10.9)
24
1
Hex head capscrew - M12x1.75x70 (grade 8.8)
6a
2
Washer
25
1
Upper spring cap
7
4
Spring locating plate
26
1
Washer
8
4
Hex head capscrew - M10x1.5x40/26 (grade 8.8)
27
1
Nyloc nut - M12x1.75
4
Hex head capscrew - M10x1.5x45/26 (grade 10.9)
28
1
Spacer bushing
9
8
Nyloc nut - M10x1.5
29
1
Steering arm
10
1
Shock absorber
30
4
Hex head capscrew - M20x2x74 (grade 10.9)
11
2
Suspension spring
Steering ISAS
12
2
Core plug
31
1
Double cardan joint
13
2
King pin
32
8
Lock nut - M10x1.5
14
2
Internal circlip
33
8
Stud - M10x1.5x70 (grade 10.9)
15
2
King pin seal
Non-steering ISAS
16
1,4
Lock wire - 4x0.35mm
34
1
Single cardan
17
2
King pin nut
35
8
Socket head capscrew - M12x1.75 (grade 10.9)
18
1
Upper wishbone
25
26
27
8
9
7
11
8
22
1 9 2 0
7
28
23
24
12
9
18
20 19 21 10
11
7
31
32 33
4
8 3
13
14
9
2
17
2
16
29
34
1 15
14
13
35
30
12
5
6
7
8
16
17
ISAS5 SEPTEMBER, 2017

1-3
Hub Reduction
3
6 3 4 2
30
29
2 6 2 8
24
1
27
23
25
5
4
10
11
12
13
14
15
19
20
16
18
21
17
22
ISAS5 SEPTEMBER, 2017

Item Qty Description
Item
Qty Description
1
1
Wheel hub assembly
16
1
Planetary spider assembly
2
10
Wheel stud
17
2
Plug
3
1
Oil seal
18
8
Hex head capscrew - M10x1.5x25/25 (grade 10.9)
4
2
Taper bearing
19
1
Special adjusting screw - M10x1.5 (grade 10.9)
5
1
Central tire inflation sealing kit
20
1
Nut
6
1
ABS ring
21
2
Copper seal
7
1
Seal race
22
2
Socket head capscrew - M6x1.0 (grade 10.9)
8
1
Planetary ring gear hub
23
10
Wheel nut
9
1
Locking washer
24
1
Stub axle assembly
10
1
Spindle nut
25
1
Knuckle
11
1
Spindle ring
26
1
Spindle
12
1
Coupling
27
2
O-ring
13
1
Sun gear
28
2
O-ring
14
1
Socket head capscrew-M14x1.5x90/40 (grade 10.9)
29
16
Socket head capscrew - M16x2.0x40/40 (grade 10.9 )
15
1
Thrust button
30
1
Sealing kit
31
1
Axle shaft
ISAS5 SEPTEMBER, 2017

,
Section 2
Disassembly
2-1
WARNING
To prevent serious eye injury, always wear
safe eye protection when you perform vehicle
maintenance orservice.
Some models are equipped for shock removal
without requiring the removal of the subframe or
springs. Review your vehicle installation before
proceeding.
Removal of Springs and Shock
Absorber
1. Remove the check strap
NOTE:Notallvehiclesareequippedwith
checkstraps. If no check strap,proceed to
step2.
3. Remove the shock absorber upper nut.
Remove the upper spring cap assembly.
Remove the shock absorber lower nut.
2. Put the wheel end in the maximum hanging
position.
4. Remove the shock absorber and the 2
springs.
WARNING
Springs must be in the fully extended position
before removal. Failure to do so could result
in serious personal injury.
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-2
Cardan Joint
NOTE: Steering ISAS uses double cardan
joints with stud and nut fasteners.
Non-steerng ISAS uses single cardan joints
with capscrew fasteners.
1. Align the wheel end with the axle.
4. Remove the fasteners from the universal
joint, on the axle housing side. Separate the
cardan joint, using a lever. Remove the
cardan joint.
Suspension
2. Remove the fasteners from the cardan joint,
on the wheel end side.
3. Separate the end of the cardan joint using a
pry bar.
WARNING
To avoid serious personal injury and damage
to components, be very careful when using
lifting devices for service and maintenance
procedures.
 Inspect tomakesurethatneitherlifting
strapisdamaged.
 Donotsubjectliftingstrapsto any
shockordrop loading.
NOTE: Refer to theSuspension exploded view
inSection1.
1. Remove the upper king pin nut.
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-3
2. Remove the lower king pin nut.
Brake Disc
3. Using a lifting strap, separate the upper
wishbone. Separate the wheel end from the
lower wishbone. Remove the wheel end.
4. Remove the fastening bolts from straddle
bearing. Remove the upper and lower
wishbones.
1. Remove the 16 brake disc bolts.
2. Remove the 4 brake caliper bolts. Withdraw
the brake caliper and the disc.
NOTE: The AxleTech 5000 ISAS usesMeritor
DX225 and DX195 Brakes. For maintenance
information on the brakes, refer to Manual
DX/1/E.
To order this publication, call ArvinMeritor’s
Customer Service Center at 800-535-5560.
ISAS5 SEPTEMBER, 2017