AxleTech 5000 Series Maintenance Manual
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AxleTech 5000 Series Maintenance Manual

Independent suspension axle system, isas5
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Issued -201
Independent Suspension
Axle System
5000 Series
Maintenance Manual ISAS5
ISAS5 SEPTEMBER, 2017

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Summary of Contents for AxleTech 5000 Series

  • Page 1 Issued -201 Independent Suspension Axle System 5000 Series Maintenance Manual ISAS5 ISAS5 SEPTEMBER, 2017...
  • Page 2 Ax l eT ec h ’s i n de p en d en t A Warning alerts you to WARNING suspension axle system ISAS 5000 Series. The an instruction or information contained in this manual was current...

  • Page 3: Table Of Contents

    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 ..................

  • Page 4: Differential

    12 13 2 0 1 9 1 8 14 15 Differential Item Qty Description Item Qty Description Axle housing Socket head capscrew - M8x1.25x25 (grade 8.8) Carrier assembly Halfshaft Breather Brake disc Filler plug Socket head capscrew - M8x1.0x35 (grade 10.9) Drain plug Brake assembly Lock nut - M48x1.5...

  • Page 5: Suspension

    1 9 2 0 20 19 21 32 33 Section 1 Exploded View Suspension Item Qty Description Item Qty Description Lower wishbone Straddle bearing Bushing Internal circlip Lower spring mounting Hex head capscrew Mounting pivot pin Bump stop Locking strip Washer Hex head capscrew - M6x1.0x20 (grade 10.9) Hex head capscrew - M12x1.75x70 (grade 8.8)

  • Page 6: Hub Reduction

    Hub Reduction 2 6 2 8 19 20 ISAS5 SEPTEMBER, 2017...
  • Page 7 Item Qty Description Item Qty Description Wheel hub assembly Planetary spider assembly Wheel stud Plug Oil seal Hex head capscrew - M10x1.5x25/25 (grade 10.9) Taper bearing Special adjusting screw - M10x1.5 (grade 10.9) Central tire inflation sealing kit ABS ring Copper seal Seal race Socket head capscrew - M6x1.0 (grade 10.9)

  • Page 8: Section 2 - Disassembly

    Section 2 Disassembly WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Some models are equipped for shock removal without requiring the removal of the subframe or springs. Review your vehicle installation before proceeding.

  • Page 9: Cardan Joint

    Section 2 Disassembly 4. Remove the fasteners from the universal Cardan Joint joint, on the axle housing side. Separate the cardan joint, using a lever. Remove the NOTE: Steering ISAS uses double cardan cardan joint. joints with stud and nut fasteners. Non-steerng ISAS uses single cardan joints with capscrew fasteners.

  • Page 10: Brake Disc

    4. Remove the fastening bolts from straddle bearing. Remove the upper and lower NOTE: The AxleTech 5000 ISAS uses Meritor wishbones. DX225 and DX195 Brakes. For maintenance information on the brakes, refer to Manual DX/1/E.

  • Page 11: Differential Halfshaft

    Section 2 Disassembly 3. Remove the differential shaft. 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.
  • Page 12 Section 2 Disassembly 4. Remove planetary spider cover unit. 1. Remove the bolts that secure the cover. 5. Remove the end thrust button. 2. Unlock and remove nut of adjusting screw. 7. Unlock the sun gear bolt. Maintain the sun gear with jet extractor of bronze.
  • Page 13 Section 2 Disassembly 7. Remove the sun gear and the coupling. 10. Use spanner # 5231 to remove the spindle nut. 8. Remove the axle shaft. 11. Remove spindle nut and lock washer. 9. Unlock spindle nut. WARNING Gear teeth can be sharp. Wear protective gloves to avoid serious personal injury.
  • Page 14 Section 2 Disassembly 14. Use a rubber mallet and drift to remove the ring gear hub taper bearing. If necessary, install the CTI guide sleeve, part number 5239, onto the spindle. 15. Remove bearing cup from hub. WARNING avoid serious personal injury and damage to components, take care when using lifting devices during service...
  • Page 15 Section 2 Disassembly For version C.T.I only 20. If necessary, remove the spindle of the knuckle. 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.

  • Page 16: Section 3 - Inspection

    Section 3 Inspection 2. W hen a b e ar in g h a s b ee n h ea te d f or WARNING assembly, apply a small amount of grease or oil after assembly. To prevent serious eye injury, always wear safe eye protection when you perform vehicle Seals maintenance or service.
  • Page 17 Section 3 Inspection 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.

  • Page 18: Section 4 - Assembly

    Section 4 Assembly 4. Apply a bead of silicone sealing compound WARNING on the face of the spindle. Observe all warnings and cautions provided ® 5. Use Loctite 242 on the screws. Tighten them by the press manufacturer concerning press to 190 lb-ft (258 Nm).
  • Page 19 Section 4 Assembly C. Place the circlips on wheel hub. 13. Install the bearing onto the hub. Pack the bearing with grease. Refer to Section 5. 11. Use the cup driver (part number 5046) to install bearing cup onto the hub. 14.
  • Page 20 Section 4 Assembly 16. Wearing protective gloves, install the bearing 17. With a lifting strap, fit the hub assembly onto cone onto the ring gear carrier. the knuckle. Hold the spindle in position. If the vehicle is equipped with central tire If the vehicle is equipped with central tire inflation: install the surface protector (part num- remove the surface protector.
  • Page 21 Section 4 Assembly 19. Install a new locking washer and a spindle 23. Bend the lock washer tangs into the grooves nut. in the wheel bearing adjusting nut. Keep the tangs at a 45 degree angle to the ring gear hub face.
  • Page 22 Section 4 Assembly 26. Maintain the sun gear with jet extractor of 29. Install the planet gear carrier cover assembly. bronze. Apply Loctite 242 to the threads of the screw. Install screw and tighten to 152 ft- Ibs (203 Nm). ®...

  • Page 23: Differential Halfshaft

    Section 4 Assembly 35. Install copper seal and level screw. Tighten to 32. Apply Loctite 243 to thrust screw 8 ft-lb (12 Nm). Differential Halfshaft 33. 1. Turn the thrust screw in until it contacts the Refer to the differential exploded view in thrust button torque 100 ft-lbs (136 Nm) Section 1.

  • Page 24: Brake Disc

    Section 4 Assembly ® ® 5. Use Loctite 242 and install the 8 screws 2. Use Loctite 242 on the 16 disc screws and Tighten to 22-30 lb-ft (30-41 Nm). tighten to 22-30 lb-ft (30-41 Nm).  Suspension Brake Disc 1.
  • Page 25 Section 4 Assembly 3. Install the internal circlips. Apply a bead of 5. For ease of assembly, preaper the king pin grease around the king pin. seal as shown below. 6. Carefully slide the seal into position. WARNING Take care when you use adhesive materials to avoid serious personal injury.
  • Page 26 Section 4 Assembly 8. Apply grease into the upper wishbone. 11. Install the king pin into the knuckle. 9. Install the core plug into the upper wisbone. 12. Pr es s into plac e. 10. Apply a bead of silicone sealing compound on 13.
  • Page 27 Section 4 Assembly 15. Install the internal circlips. 18. With a lifting strap, install the wheel end assembly into the lower wishbone. Hand- tighten the lower king pin nut. NOTE: For installing straddle bearing into the axle housing, refer to steps 11-12. ®...

  • Page 28: Cardan Joint

    Section 4 Assembly Cardan Joint Shock Absorber (Top Post Shock) NOTE: Steering ISAS uses double cardan 1. Install the springs and shock absorber. Install joints with stud and nut fasteners. Non- the upper spring cap. For ease of assembly, steering ISAS uses single cardan joints with maintain with tool (part number 5295).

  • Page 29: Section 5 - Lubrication

    Regrease every 3000 miles (4800 km) or quar- terly. Use a lithium soap grease with a consis- tency of Class 2 or better. Use AxleTech STC 05- 203 per MIL-PRF-10924. Do not use grease with additive.

  • Page 30: Section 6 - Special Tools

    Section 6 Special Tools Special Tools Drawings Driver handle - 5021 Hub seal driver - 5203 Cup driver - 5046 Washer - 5204 ISAS5 SEPTEMBER, 2017...
  • Page 31 Seal driver - 5207 CTI seal driver - 5237 Spanner wrench - 5231 CTI seal driver - 5238 ISAS5 SEPTEMBER, 2017...
  • Page 32 Section 6 Special Tools Protector - 5239 Bearing driver - 5294 King pin muff - 5293 Shock absorber clamp - 5295 ISAS5 SEPTEMBER, 2017 October 2015 ISAS5...
  • Page 33 REVISIONS T. Betena 09/20/2017 Updated torque requirements from 155lb-ft to 90-110 ft-lb on page 4-6 #33 per Tammy Marsh. ISAS5 SEPTEMBER, 2017...

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