AxleTech PSC1044 Service Manual Download Page 1

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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

Summary of Contents for PSC1044

Page 1: ...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 ...

Page 2: ... 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 A...

Page 3: ...ssible 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 ...

Page 4: ...d 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...

Page 5: ...thod 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...

Page 6: ...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 T...

Page 7: ... 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 shaf...

Page 8: ...ince 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 situ...

Page 9: ...ith 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 ...

Page 10: ...roperly 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 damag...

Page 11: ...asteners 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 s...

Page 12: ...ns 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 BO...

Page 13: ...mbers 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 Designatio...

Page 14: ...ing 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 Kn...

Page 15: ...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 S...

Page 16: ...her 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 r...

Page 17: ...ing 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...

Page 18: ... 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 ...

Page 19: ...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 ...

Page 20: ...e 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 s...

Page 21: ...ers have loosened from the bearing caps Remove the retainers from the arms of the cross through the hole in the yokes 4 Turn the vertical yoke over Repeat Step 3 to remove the needle bearing and retainer on the opposite side 5 Remove the yoke by gently moving the yoke oﬀ the arms of the cross 6 Hold the remaining yoke in a vertical position and rest the cross arms on top of the open vise Repeat St...

Page 22: ...rom the long shaft If there is a snap ring at the inner end of the long shaft spline Remove the snap ring before removing the boot Preparing Parts for Assembly Cleaning WARNING SOLVENT CLEANERS CAN BE FLAMMABLE POISON OUS AND CAUSE BURNS EXAMPLES OF SOLVENT CLEANERS ARE CARBON TETRACHLORIDE EMUL SION TYPE CLEANERS AND PETROLEUM BASED CLEANERS TO AVOID SERIOUS PERSONAL INJURY WHEN USING SOLVENT CLE...

Page 23: ...housing bowl before assembling the axle Assembly and Installation WARNING TO PREVENT SERIOUS EYE INJURY ALWAYS WEAR EYE PROTECTION WHEN PERFORMING VEHICLE MAINTE NANCE OR SERVICE 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 Assembly of Steering Universal Joint Roun...

Page 24: ...outer lock ring stainless strapping and a lock clip for one shaft assembly 1 Inspect the constant velocity joint bell housing and race assembly for the correct amount of grease approximately 12 ounces The grease level should be at the back side of the inner race as viewed through the internal spline of the inner race NOTE Grease should be placed around each ball in race and into boot fold cavities...

Page 25: ...he bell housing groove CAUTION NEVER USE EXCESSIVE HAMMER FORCE TO FLATTEN THE CLIP EARS OVER THE STRAP END DAMAGE TO THE STRAP BUCKLE OR BOOT CAN OCCUR FROM EXCES SIVE HAMMER FORCE TAKE CARE NOT TO CREATE A TEAR IN BOOT MATERIAL WHEN TIGHTENING THE STRAP CLIP ASSEMBLY 13 Verify the boot and strap are positioned correctly Use a hammer to ﬂatten the clip ears over the strap end to lock it in NEVER ...

Page 26: ...of King Pin Bushings Non Sealed King Pin Bushings 1 Verify the housing bore is clean Use an emery cloth to remove burrs 2 Use an appropriate driver to install a new bushing Use the old bushing to drive the new bushing to the bottom of the housing bore chamfer TACK WELD FOUR PLACES Bushing must be pressed to bottom of chamfer NOTE Bushing must be pressed to bottom of housing bore chamfer If the kin...

Page 27: ...into the housing bore until the ﬂange is tightly seated on the housing boss face SEALED DESIGN FLANGED BUSHING If the bushing is tight in the housing bore Insert a king pin cap in the bushing Use a plastic mallet or bronze drift on the cap to drive the bushing into the housing Drive the bushing into the bore until the bushing ﬂange is tightly seated on the housing boss face NOTES Kit MPS 4470 has ...

Page 28: ...nuckle over the axle housing trunnion end Align the king pin bore in the knuckle with the axle housing king pin bushing NOTE NEVER install the grease seal on the sealed design cap The seal is installed after adjusting the knuckle vertical end play 14 3 3 4 5 6 7 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 Knuck...

Page 29: ... knuckle bore at this time 2 Install the cap into the knuckle Tighten the mounting screws alternately in small increments to keep the cap straight in the knuckle bore 3 Tighten the capscrews DO NOT apply ﬁnal torque until the knuckle end play has been set Steer Knuckle Adjustment Knuckle vertical end play is adjusted with shims between the king pin caps and the steer knuckle Use one of the fol low...

Page 30: ...nd play using the following procedure Adjust Knuckle Vertical End Play 1 Remove the upper and lower king pin caps Remove the shim packs and measure the total shim pack thickness upper plus lower shim pack thickness Record the total thickness 2 Subtract the actual measured end play Step 3B above from the total thickness Divide the result by 2 3 Adjust the lower shim pack thickness to equal the valu...

Page 31: ...e Tighten the capscrews alternately in small increments to keep the cap straight in the knuckle bore See Torque Speciﬁcations on page 22 3 Install the new shim pack on the lower king pin cap 4 Grease the grooved face of the lower thrust washer Place the washer on the king pin cap with the grooved face contacting the king pin cap surface CAUTION THE THRUST WASHER TANGS MUST ENGAGE THE SLOTS IN THE ...

Page 32: ...al when installing the axle shaft Spindle Brake Planetary Wheel End Refer to the appropriate planetary wheel end service man ual for spindle brake and planetary wheel end installa tion procedures To obtain these publications refer to the Service Notes section in this manual For measuring and adjusting the toe setting procedures refer to the following publications ESM 0093 Planetary Rigid Steer Axl...

Page 33: ...56 7 8 14 200 250 271 339 1 1 4 12 400 550 542 746 1 1 2 12 475 550 644 746 3 Steer Stop Bolt Jam Nut 1 2 13 50 65 68 88 7 8 14 150 190 203 258 1 14 250 300 339 407 1 1 4 12 275 350 373 475 1 1 2 12 300 400 407 542 4 Tie Rod Ball Stud Jam Nut 1 16 165 200 224 271 1 1 4 12 165 200 224 271 5 Ball Joint End Tie Rod Clamp Bolt 5 8 18 80 90 108 122 1 2 20 35 45 47 61 5 8 18 PSC5494 only 90 100 122 136 ...

Page 34: ...14 2 PSTC824 30 14 2 PSC825 30 14 2 PSC826 37 17 5 PSC1044 40 18 9 PSC1045 40 18 9 PSC1485 44 20 8 PSC1614 40 18 9 PSC1615 40 18 9 PSC1617 40 18 9 PSC1764 40 18 9 PSC1794 R155 52 24 6 PSC1794 RS160 PSC1875 56 26 4 PSC1876 54 25 5 PSC4564 58 27 4 PSC4565 58 27 4 PSC5494 64 30 2 Typical lube quantities are indicated as estimates due to the multiple axle housing length options available Actual volume...

Page 35: ...Appendix 24 Appendix Torque Speciﬁcations ...

Page 36: ...Appendix 25 ...

Page 37: ... example 1 2 Number of Threads in 1 a Measure the diameter of the threads in inches dimension X b Count the amount of threads there are in 1 Example American Standard size fastener is 0 50 13 00 0 50 is the diameter of the fastener in inches or dimension X 13 00 is the amount of threads in 1 Measuring Metric Fasteners Pitch X Dimension For example M8 or 8mm Y Dimension Distance of 10 Threads a Mea...

Page 38: ... registered trademarks of their respective owners Information supplied by AxleTech is believed to be accurate and reliable AxleTech reserves the right without notice to makes changes in product design or specifications Customer Service 877 547 3907 33 0 4 77 92 88 92 Customer Service Fax 877 547 3987 Email OE sales axletech com Aftermarket aftermarket axletech com www axletech com ASM 0910E 10 19 ...

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