AxleTech TA277, Service Manual

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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 fi ne fi le, India
stone, emery cloth or crocus cloth for this purpose.
Torque Specifi cations
• Tightening torque specifi cations 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.
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 fi ne fi le 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.
Cleaning
1. Remove gasket material using a gasket scraper taking
care not to damage machined surfaces.
2. Steam clean or pressure wash the assembly after
plugging all breathers and vents.
NOTE: NEVER direct full pressure at any of the seals (input
shaft, wheel hubs, or brakes).
3. Use solvent cleaners or alkaline solutions to clean
all metal parts with rough surfaces. Rinse alkaline
solution off with water after cleaning.
4. 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.
5. Dry all parts after washing using clean rags or paper
towels.
6. Apply a light oil fi lm to all parts to be reused and
reassembled.
7. 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.