AxleTech TA277 Service Manual Download | Manualshive

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Gearbox Assembly

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Disassembly

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Summary of Contents for TA277

Page 1: ...Trans Axles ASM 0277E SERVICE MANUAL October 2018 TA277 ...

Page 2: ...ng Carrier 5 Checking Gearbox Oil 5 Draining Gearbox 6 Filling Gearbox 6 Illustrations 7 Top View 7 Front View 7 Rear View 8 Housing 9 Exploded View 9 Disassembly 12 Gearbox Assembly 13 Exploded View 13 Disassembly 15 Assembly 17 Axle Sub Assemblies 19 Exploded View 19 Disassembly 21 Assembly 23 Brake Assembly 25 Exploded View 25 Disassembly 27 Pad Removal 28 Caliper Overhaul 29 Caliper Assembly 3...

Page 3: ...cle 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 ...

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: ...ORE 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 MANU FACTURER FOR PROPER JACKING AND SUPPORT METHODS WARNING FOLLOW THE SPECIFIED PROCEDURES IN THE INDICAT ED ORDER TO AVOID PERSONAL INJURY OR EQUIPMENT MA...

Page 7: ...g 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 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 ...

Page 8: ...ings 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 bearing...

Page 9: ...n During disassembly In the event of sticking heat the screws 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 During assembly Apply one drop to the threads preferably at the end of the screw of Loctite 2...

Page 10: ...ust be ordered from AxleTech International Any damage to parts not described in this manual must be repaired or replaced using original parts Technical Speciﬁcations Model TA277 Capacity 6 000 lbs 2 700 kg Axle type Full ﬂoating rigid axle Final ratio 12 33 14 14 17 00 17 57 or 20 00 Housing Ductile iron center section with steel tubes Wheel mounting Hub piloted 8 stud 6 50 in 165 mm bolt circle w...

Page 11: ...ase Have reference numbers handy when ordering replacement parts or requesting service repairs DO NOT REMOVE OR DESTROY THE IDENTIFICATION TAG Model Nomenclature TA 277 HDB 208 XXX Base Model Number 267 Non planetary 268 Planetary Wheel End 277 Non planetary Type TA Trans Axle Specification Brakes DSH Duo Servo Hydraulic HDB Hydraulic Disc NX None Carrier Ratio ...

Page 12: ...he carrier procedures outlined in Draining Carrier on page 4 and Filling Carrier on page 5 Follow the wheel end procedures outlined in Draining Gearbox on page 6 and Filling Gearbox on page 6 Verify the oil is to the proper level as explained in Checking Carrier Oil on page 4 and Checking Gearbox Oil on page 5 Lubrication With any product containing gears lubrication is possibly the most important...

Page 13: ... at the proper level Filling should be done slowly to provide enough time to ensure the oil ﬂows through the complete assembly 4 Clean and apply pipe thread sealant to the oil ﬁll plug and tighten to 35 lbs ft 48 N m minimum Draining Carrier Draining should be done immediately following vehicle operation when the oil is warm 1 Place a drain pan underneath the unit 2 Remove the magnetic oil drain p...

Page 14: ...N m minimum Checking Gearbox Oil 1 Remove the oil level plug see Oil Level location below Gear Box Oil Drain Plug Gear Box Oil Fill Plug Correct Oil Level 2 Verify oil is at the proper level by conﬁrming it is even with the bottom of the oil level opening When the plug is removed to check the level oil should actually seep out Do not use your ﬁnger to feel for the oil Even if you can touch the oil...

Page 15: ...ng to local requirements Filling Gearbox 1 Ensure the vehicle is parked on a level surface 2 Remove the oil ﬁll plug located on the front of the gearbox case Gear Box Oil Drain Plug Gear Box Oil Fill Plug Correct Oil Level 3 Add the recommended oil type and quantity until it is at the proper level using the Fill Hole see illustration above Filling should be done slowly 4 Verify oil is at the prope...

Page 16: ...Illustrations Top View Short Shaft Assembly Long Shaft Assembly Carrier Gear Box Wheel End Assembly 1x75 Brake Bleeder Input Shaft Front View Carrier Oil Drain Plug Carrier Oil Fill Plug Breather Parking Brake Assembly ...

Page 17: ...Illustrations 8 Rear View Gear Box Oil Drain Plug Gear Box Oil Fill Plug ...

Page 18: ...41 40 46 45 44 34 99 98 94 49 43 42 39 37 38 37 92 91 3 4 5 6 7 22 23 26 25 43 47 48 49 27 28 29 36 93 57 58 61 83 81 82 76 69 72 75 73 72 71 71 74 97 96 89 62 55 56 57 58 1 2 65 64 84 85 86 88 87 50 51 66 62 89 79 78 77 80 16 17 35 32 33 59 53 95 63 60 54 52 90 70 67 68 8 20 31 30 ...

Page 19: ...3 Capscrew 43 Bearing Cone 14 Spacer 44 Magnetic Oil Drain Plug 15 Caliper Bracket 45 Washer 16 Washer 46 Nut 17 Nut 47 Pinion Cage Assembly 18 Washer 48 Shim Kit 19 Capscrew 49 Bearing Cup 20 Capscrew 50 Bearing 21 Parking Brake Rotor 51 Snap Ring 22 Roll Pin 52 Ring Gear Pinion Assembly 23 Stud 53 Capscrew 24 Gearbox Case 54 Diﬀerential Case Plain Half 25 Bearing 55 Thrust Washer 26 Input Gear 5...

Page 20: ...r Plain Half Tube Weldment 86 Breather Assembly 67 Axle Shaft 87 Coupling 68 Shaft Assembly 88 Nipple 69 Cotter Pin 89 Bearing Cone 70 Sleeve 90 Nut 71 Bearing Cone 91 Washer 72 Bearing Cup 92 Capscrew 73 Bearing Housing 93 Spider 74 Washer 94 Diﬀerential Service Kit 75 Capscrew 95 Washer 76 O ring 96 Plug 77 Wheel Stud 97 Capscrew 78 Wheel Hub 98 Slide Pin 79 Brake Rotor 99 Brake Assembly 80 Nut ...

Page 21: ... Disassembly RLVW WKH D OH WR D IL WXUH DQG VHFXUH 5HPRYH WKH SOXJ IURP WKH JHDUER WR GUDLQ WKH RLO 5HPRYH WKH SOXJ IURP WKH FDUULHU WR GUDLQ WKH RLO See Draining Gearbox on page 6 See Draining Carrier on page 4 ...

Page 22: ...Gearbox Assembly 13 Gearbox Assembly Exploded View 5 17 18 19 20 11 23 21 24 26 25 27 6 9 10 14 16 15 12 13 8 7 22 1 3 4 2 ...

Page 23: ...rew 3 Flange 17 Oil Fill Plug 4 Oil Seal Assembly 18 Capscrew 5 Stud 19 Gearbox Cover 6 Gearbox Case 20 Dowel 7 Washer 21 Nut 8 Nut 22 Woodruﬀ Key 9 Bearing 23 Driven Gear 10 Input Gear 24 Spacer 11 Lock Plate 25 Magnetic OIl Drain Plug 12 Bearing 26 Washer 13 Snap Ring 27 Nut 14 Bearing Cover ...

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Page 26: ... QHZ RLO VHDO DVVHPEO LQWR WKH JHDU ER FDVH ERUH XVLQJ 6HDO ULYHU 7 QVWDOO WKH ORFN SODWH DQG QXW Ź OEV IW 1āP VVHPEOH WKH LQSXW VKDIW 3UHVV ERWK EHDULQJV RQWR WKH LQSXW VKDIW QVWDOO WKH VQDS ULQJ RQWR WKH VKDIW 5HPRYH WKH 2 VQDS ULQJ WKDW FRPHV RQ WKH RXWHU EHDULQJ SODFH WKH VKDIW WKURXJK WKH JHDU ER FRYHU DQG DWWDFK VKDIW WR FRYHU ZLWK VQDS ULQJ After applying Loctite to the pinion cage check th...

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Page 28: ...Axle Sub Assemblies 19 Axle Sub Assemblies Exploded View 1 3 4 14 12 13 10 2 2 11 4 3 21 20 8 9 17 1 15 19 19 17 5 6 7 7 6 7 7 5 3 3 18 16 18 ...

Page 29: ...g 3 Brake Assembly 14 Breather Assembly 4 Slide Pin 15 Capscrew 5 Hub Assembly 16 Washer 6 Sleeve 17 Capscrew 7 Torque Plate 18 Carrier Plain Half Tube Weldment 8 Carrier Flange Half Tube Weldment 19 Bearing Cup 9 Parking Brake Assembly 20 Washer 10 Gearbox Assembly 21 Nut 11 Diﬀerential Assembly ...

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Page 34: ...Brake Assembly 25 Brake Assembly Exploded View 1 3 4 5 6 7 8 9 10 13 12 11 14 2 ...

Page 35: ...ion Item Description 1 Stator Clip 8 Rubber Ring 2 Outboard Pad Assembly 9 Caliper Assembly 3 Inboard Pad Assembly 10 Protective Plug 4 Stator Clip 11 Rubber Ring 5 Piston Boot 12 Sleeve 6 Seal 13 Slide Pins 7 Piston 14 Bleeder Screw ...

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Page 42: ...Disc Brake Assembly 33 Disc Brake Assembly Exploded View Alternate Brake Option 1 2 4 5 6 7 8 10 9 6 3 A B C D T E F G H I J K L M N O P Q R S ...

Page 43: ...ket 8 Lock Nut 9 Spacer 10 Bushing Item Description A Adjusting Bolt B Torque Plate Rear C Spring D Sleeve Seal E Torque Plate Front F Nut G Mounting Bolt H CCW Cam I Boot J ID Seal K Lever L Thrust Washer M Washer N Adjustment Nut O Adjustment Nut P Washer Q Ball Bearing R Retainer S Mounting Sleeve T Lining Carrier Assembly ...

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Page 46: ...Hub Assembly 37 Hub Assembly Exploded View 1 2 6 9 10 3 12 5 4 8 7 11 ...

Page 47: ...ssembly 38 Item Description Item Description 1 Wheel Hub 7 Washer 2 Wheel Stud 8 Bearing Housing 3 Oil Seal Assembly 9 Spacer 4 Bearing Cone 10 Bearing Cup 5 Bearing Cup 11 Bearing Cone 6 Capscrew 12 O ring ...

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Page 50: ...Diﬀerential Assembly 41 Diﬀerential Assembly Exploded View 11 12 13 17 14 16 14 16 1 3 1 3 8 7 4 4 6 5 21 20 10 9 18 2 19 15 ...

Page 51: ...Bearing 2 Diﬀerential Case Plain Half 13 Pinion 3 Thrust Washer 14 Bearing Cone 4 Side Gear 15 Spacer 5 Pinion Gear 16 Bearing Cup 6 Thrust Washer 17 Pinion Cage 7 Ring Gear 18 Capscrew 8 Diﬀerential Case Flange Half 19 Spider 9 Nut 20 Washer 10 Washer 21 Capscrew 11 Snap Ring ...

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Page 56: ...Housing 47 Housing Assembly QVWDOO XQLW LQWR YHKLFOH QVWDOO WKH RLO GUDLQ SOXJ GG RLO WR WKH JHDU ER QVWDOO WKH RLO GUDLQ SOXJ GG RLO WR WKH FDUULHU ...

Page 57: ...Appendix 48 Appendix Torque Speciﬁcations ...

Page 58: ...Appendix 49 ...

Page 59: ...50 Tools Hub Bearing Cup Driver TC 80324 Hub Seal Driver TC 80077 Hub Base TC 80275 Hub Bearing Pilot TC 80277 1 Hub Bearing Driver TC 80277 2 Bearing Housing Base TC 80278 DET1 ...

Page 60: ...51 Bearing Housing Leg TC 80278 DET2 Cap TC 80278 DET3 Adjusting Ring TC 80321 Bearing Cup Driver TC 67676 Seal Driver TC 69097 Bearing Cone Driver TC 66987 Bevel Gear Torque Fixture TC 79556 DET4 ...

Page 61: ......

Page 62: ... 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 0277E 10 18 ...

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