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

Section 2
Disassembly
2-4
Differential Halfshaft
NOTE: Refer to the Differential exploded view
in Section 1.
Remove the plug from the bottom of the axle
housing. Drain the lubricant from the assembly.
NOTE: Before removing the axle shaft the
differential lock must be positively engaged.
 Removethedifferentiallockcylinder.
See process in Field Maintenance
Manual MM1 or MM2.
 Engagethedogclutch whilepullingthe
fork and turning a wheel.
 Holdtheforkwithawiretokeepthedog
clutch engaged.
1. Remove the 8 differential shaft bolts.
2. Use a pry bar to separate the differential
shaft.
3. Remove the differential shaft.
4. Unlock and remove the shaft nut. Remove the
lock washer, the ball bearing and the seal
housing. Extract the oil seal from the seal
housing.
NOTE: Formaintenance information on the
differential see specific manuals:
Final drive axle: MM1.
Thru drive axle: MM2.
Hub Reduction
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-5
1. Remove the bolts that secure the cover.
2. Unlock and remove nut of adjusting screw.
5. Remove the end thrust button.
7. Unlock the sun gear bolt. Maintain the sun
gear with jet extractor of bronze.
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-6
7. Remove the sun gear and the coupling.
8. Remove the axle shaft.
9. Unlock spindle nut.
10. Use spanner # 5231 to remove the spindle
nut.
11. Remove spindle nut and lock washer.
WARNING
Gear teeth can be sharp. Wear protective
gloves to avoid serious personal injury.
12. Wearing protective gloves, remove the ring
gear carrier.
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-7
If necessary, install the CTI guide sleeve, part
number 5239, onto the spindle.
WARNING
To avoid serious
personal injury and damage to components,
take care when using lifting devices during
service and maintenance procedures.
Inspect a lifting strap to ensure that it is not
damaged. Do not subject lifting straps to
shocks or drop-loading.
13. Use a lifting strap to remove the hub
assembly. If bearing and seal have not been
taken out together with the hub, remove them
from the spindle. If necessary, remove the
spindle end ring.
WARNING
Use a rubber mallet for
assembly and
disassembly procedures. Do not hit steel
parts with a steel hammer. Pieces of a part can
break off and cause serious personal injury.
14. Use a rubber mallet and drift to remove the
ring gear hub taper bearing.
15. Remove bearing cup from hub.
For version C.T.I only
16. Remove the circlips.
ISAS5 SEPTEMBER, 2017

Section 2
Disassembly
2-8
For version C.T.I only
17. Remove outside ring. Remove outside seal,
the inner seal and the guide ring.
18. Return the hub. Remove seal, bearing cup
and bearing from hub.
19. Remove the oil seal and the bearing from the
knuckle.
20. If necessary, remove the spindle of the
knuckle.
ISAS5 SEPTEMBER, 2017

Section 3
Inspection
3-1
WARNING
To prevent serious eye injury, always wear
safe eye protection when you perform vehicle
maintenance orservice.
Tapered Roller Bearings
If the parts are clean and correctly lubricated, it is
rare to find damaged bearings during removal.
Therefore, avoid removing them because they
may be damaged by the puller.
Remove bearings with the following conditions:
1. Worn or damaged bearing surface.
2. Chipped bearing or damaged bearing surface
3. Incorrect lubrication.
4. Broken part in the mechanism.
WARNING
Solvent cleaners
can be flammable, poisonous and cause
burns. Examples of solvent cleaners are
carbon tetrachloride, emulsion-type cleaners
and petroleum based cleaners. To avoid
serious personal injury when you use
solvent cleaners, you must carefully follow
the manufacturer’s product instructions and
these procedures:
 Wearsafeeye protection.
 Wear clothing that protects your skin.
 Work in a well-ventilated area.
 Donotusegasoline,orsolventsthat
contain gasoline. Gasoline can explode.
 Usehotsolutiontanksoralkaline
solutionscorrectly.Followthe
manufacturer’s instructions carefully.
Bearing Assembly Precautions
If the bearing is new, unpack it just before
assembly. If the bearing is reusable, clean it with
solvent-base cleaner and then oil it.
1. When it is possible, install the bearing parts
by cooling (in liquid nitrogen) or by heating (in
hot oil to 80°C [176°F]) instead of using a
press. A press is preferred to a shock installer
tool. The bore must be carefully deburred and
cleaned before assembly of the bearing.
2. W hen a be aring has been hea te d for
assembly, apply a small amount of grease or
oil after assembly.
Seals
1. O-rings: After removal, replace them with
new O-rings.
2. Lip seals: Change lip seals with new seals at
each removal. The bore must be carefully
deburred and greased before installing the
seal. The fitting of the seal on the seal
surface is always difficult; use care not to
damage the lip seals when installing them.
NOTE: It is better to install a seal with a press
than with a shock installer tool.
Replacing a Wheel Stud
In case of a breakage or a stripping of a wheel
stud it must be replaced. Generally it is
unnecessary to remove the hub to change it. Use
a drift and a hammer to remove the stud. The new
stud may be installed with a hammer or press fit.
Fasteners
For bolts with pre-applied microcapsulating after
removal use Loctite SR 242.
WARNING
Take care when you use
Loctite
®
to avoid serious personal
injury. Follow the manufacturer’s
instructions to prevent irritation to the eyes
and skin.
TighteningTorques
The tightening torques indicated in this manual
must be followed:
A tightening torque lower than indicated may lead
to a shearing stress and may break the bolt.
A higher tightening torque may lead to a plastic
deflection of the bolt and damage of the parts.
ISAS5 SEPTEMBER, 2017

Section 3
Inspection
3-2
Sealing of Mounting Surfaces
WARNING
Take care when you use
silicone gasket materials to avoid serious
personal injury. Follow the manufacturer’s
instructions to prevent irritation to the eyes
and skin.
Small amounts of acid vapor are present when
applying silicone gasket material. To prevent
possible serious personal injury, make sure
there is good ventilation in the work area. If
the silicone gasket material gets in your eyes,
flush your eyes with water for 15 minutes.
Have youreyes checked by a doctor.
ISAS5 SEPTEMBER, 2017

Section 4
Assembly
4-1
WARNING
Observe all warnings and cautions provided
by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components.
1. Install the steering arm. Use Loctite
®
242 on
the screws. Install screws and tighten them to
200-258 lb-ft (271-350 Nm).
Installation
NOTE: Refer to Section 6 for drawings of the
tools specified in these procedures.
Hub Reducer
1. Apply Loctite 680 on the outer diameter of the
spindle ring. Install the spindle ring into the
end of the spindle.
2. Put one O’ring on the spindle.
3. Put the other O’ring in the groove of the
knuckle.
4. Apply a bead of silicone sealing compound
on the face of the spindle.
5. Use Loctite
®
242 on the screws. Tighten them
to 190 lb-ft (258 Nm).
6. Use a driver (part
number 5294) to insert a lightly greased
needle bearing into the spindle.
7. Use a seal driver (part number 5207) to
insert the seal.
8. Grease the lower edges of the seal.
9. Use Loctite
®
510 on spindle and fit seal race
after heating it to 210-250°F.
10. If the vehicle is equipped with central tire
inflation, follow steps A-C, below.
NOTE: Lightly lubricate the seal lips.
A. Install onto the hub the guide ring, the inner
seal use a seal driver (part number 5237).
B. Install the outside seal use a seal driver (part
number 5238) and the outside ring.
ISAS5 SEPTEMBER, 2017

Section 4
Assembly
4-2
C. Place the circlips on wheel hub.
11. Use the cup driver (part number 5046) to
install bearing cup onto the hub.
12. Use the cup driver (part number 5046) to
install bearing cup onto the hub.
13. Install the bearing onto the hub. Pack the
bearing with grease. Refer to Section 5.
14. Use a seal driver (part number 5203) to install
the oil seal.
NOTE: Lightly lubricate the seal lips.
WARNING
Components will be hot. Wear protective
gloves to avoid serious personal injury.
15. Heat the bearing cone to 175°F (79°C).
ISAS5 SEPTEMBER, 2017

Section 4
Assembly
4-3
16. Wearing protective gloves, install the bearing
cone onto the ring gear carrier.
17. With a lifting strap, fit the hub assembly onto
the knuckle. Hold the spindle in position.
If the vehicle is equipped with central tire
inflation: install the surface protector (part num-
ber 5239) onto the spindle.
WARNING
To avoid serious personal injury and
damage to components, take care when
using lifting devices during service and
maintenance procedures. Inspect a lifting
strap to ensure that it is not damaged. Do
notsubject lifting straps toshocksordrop-
loading.
If the vehicle is equipped with central tire
inflation:
remove the surface protector.
WARNING
Gear teeth can be sharp. Wear protective
gloves to avoid serious personal injury.
18. Wearing protective gloves, install the ring
gear with its bearing onto the gear carrier.
Align the gear splines with the hub splines.
ISAS5 SEPTEMBER, 2017