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NAVEDTRA 14050a Manual

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Trailer connections. Both the tractor and trailer have a seven-terminal trailer
receptacle that accepts the trailer electrical cable plug (Figure 6-54). Trailers used as a
part of double and triple trailers have trailer receptacles at both the front and rear of the
trailer to provide interconnection between trailers and dollies.
Figure 6-54 - Tractor-trailer connectors.
Because most tractors do not pull the same trailer all the time, the trailer receptacle and
cable are standardized throughout North America. The trailer interconnection is defined
by SAE recommended practice J560. Each of the seven circuits on all trucks and
trailers should be wired in the prescribed manner to permit tractors and trailers
throughout North America to be interchangeable.
NAVEDTRA 14050A
6-53

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  • Page 1 North America. The trailer interconnection is defined by SAE recommended practice J560. Each of the seven circuits on all trucks and trailers should be wired in the prescribed manner to permit tractors and trailers throughout North America to be interchangeable. NAVEDTRA 14050A 6-53...
  • Page 2 This reduces the voltage at the trailer lamps. Wire gauge is especially important for double NAVEDTRA 14050A 6-54...
  • Page 3 Stop lamps and antilock devices Right-hand turn signal and hazard • Green signal Tail, combined rear clearance, and  Brown license plate Blue Auxiliary, option lamps, dome, etc. Figure 6-56 - Schematic layout of a trailer electrical system. NAVEDTRA 14050A 6-55...
  • Page 4 Figure 6-57 - Tractor and trailer mating ends. Figure 6-58 - Trailer power distribution module. NAVEDTRA 14050A 6-56...
  • Page 5 Figure 6-59 - Trailer PDM installation. NAVEDTRA 14050A 6-57...
  • Page 6 8 gauge Figure 6-60 - Recommended wire gauges for trailer wiring. Figure 6-61 is a quick reference for troubleshooting electrical systems. It is always recommended to refer to the service manual for detailed information for troubleshooting and repairs. NAVEDTRA 14050A 6-58...
  • Page 7 4. Horn switch - steering wheel- or steering column-mounted switch for completing horn circuit Figure 6-62 shows a basic horn system. Power is present at the horns and in the harness whenever the ignition switch is turned on. The horns switch grounds the circuit to activate the horns. NAVEDTRA 14050A 6-59...
  • Page 8 Figure 6-63. It is made up of the following components: 1. Horn coil - set of windings that produce magnetic field when energized by current Figure 6-63 - Cutaway view of a horn. flow NAVEDTRA 14050A 6-60...
  • Page 9 11.6.0 Small Accessory Motors 11.6.1 Windshield Wipers A typical windshield wiper system is made up of a switch, wiper motor assembly, wiper linkage, wiper arms, and wiper blades. Either a fuse or circuit breaker protects the system. NAVEDTRA 14050A 6-61...
  • Page 10 If the fluid still streams out, the problem is after that new disconnect. If the fluid does not flow out, the problem is before the hose was disconnected. Repeat this process until the problem is found. NAVEDTRA 14050A 6-62...
  • Page 11 If the motor or the switches are found to be bad, they should be replaced. With hard-to-find problems, refer to the service manual wiring diagram for the power windows, which will show all the components that could affect power window operation and help with troubleshooting. NAVEDTRA 14050A 6-63...
  • Page 12 It is uncommon for the mechanic to get through even one day without referring to a service manual or technical literature. Specialized tools, test equipment, and other diagnostic equipment, as well as service manuals and technical literature, are rapidly becoming a necessary requirement. NAVEDTRA 14050A 6-64...
  • Page 13 The text lists three types of alternator belts. Which of the following is not an alternator belt? ribbed V-belt conventional V-belt ribbed belt cogged V-belt Which component of the alternator feeds the diode trio? stator rotor rectifier diode feeder NAVEDTRA 14050A 6-65...
  • Page 14 True False While testing a 12-volt system, the voltmeter reads 15 volts. What is the reason for this high output? Blown fuse Shorted field wire Grounded field Current limiter relay of the regulator NAVEDTRA 14050A 6-66...
  • Page 15 A steep peak every sixth pulse On a vehicle equipped with a 24-volt series parallel starting system, what minimum voltmeter reading is considered normal for a cranking voltage test? 12 volts 14 volts 16 volts 18 volts NAVEDTRA 14050A 6-67...
  • Page 16 Hall-effect pickup Trigger wheel Permanent magnet Pickup coil In the distributorless ignition system, what component consists of two or more ignition coils? power distribution module distributorless coil module ignition module electronic coil module NAVEDTRA 14050A 6-68...
  • Page 17 Switch intermittently, vertical sides, top arched reaching reference voltage, and bottom should reach zero (True or False) In a direct ignition coil test, you will measure both primary and secondary winding resistance. True False NAVEDTRA 14050A 6-69...
  • Page 18 The cab electrical system The special insulation material used in a fusible link has what characteristics? Melts off and is flammable Does not melt off nor support flame Does not melt off but is flammable None of the above NAVEDTRA 14050A 6-70...
  • Page 19 The tractor normally provides the circuit protection for trailer wiring or can have a separate component mounted on the tractor. What is the additional component with fuses and relays for trailers called? Electrical relay system Power delivery box Power distribution module Tractor/trailer power transmitter NAVEDTRA 14050A 6-71...
  • Page 20 When troubleshooting an inoperative power window, you can hear a humming noise where the motor is spinning, but there is no movement of the window. What may be the problem? Stripped plastic gears Stripped window cam Bent tracking system Stripped plastic rotor NAVEDTRA 14050A 6-72...
  • Page 21 Auto Engine Performance and Drivability, Chris Johanson, The Goodheart-Wilcox Company, Inc., 2004. (ISBN: 1-59070-257-3) Automotive Technology, A Systems Approch, 4 Edition, Jack Erjavec, Thomas, Delmar Learning, 2005. ((SBN: 1-4018-4831-1) Auto Electricity and Electronics, James Duffy, The Goodheart-Wilcox Company, Inc., 2004. (ISBN: 1-59070-272-7) NAVEDTRA 14050A 6-73...
  • Page 22 Technical Review Committee. Thank you for your assistance. Write: CSFE N7A 3502 Goodspeed St. Port Hueneme, CA 93130 FAX: 805/982-5508 E- mail: CSFE_NRTC@navy.mil Rate_ Course Name Revision Date Chapter Number Page Number(s) Description (Optional) Correction (Optional) Your Name and Address NAVEDTRA 14050A 6-74...
  • Page 23 2. Understand the principles of and how to troubleshoot automatic transmissions. Prerequisites This course map shows all of the chapters in Construction Mechanic Advanced. The suggested training order begins at the bottom and proceeds up. Skill levels increase as you advance on the course map. NAVEDTRA 14050A...

  • Page 24: Features Of This Manual

    When you have completed your review, select anywhere in that area to return to the review question. Try to answer the question again. NAVEDTRA 14050A...
  • Page 25 Releasing the clutch pedal permits the clutch fork to disengage the release bearing, so the springs will again cause the pressure plate to force the friction disc against the flywheel face to rotate together. NAVEDTRA 14050A...
  • Page 26 Hydraulic types of clutch operating systems are normally found in heavy construction equipment where extreme pressure is required to operate the clutch. Figure 7-3 - Clutch linkage. Figure 7-5 - Hydraulic clutch. Figure 7-4 - Clutch cable. NAVEDTRA 14050A...
  • Page 27 Dragging may be caused by any of the following conditions: • Excessive free travel in the clutch linkage • The clutch disc binding on the transmission input shaft NAVEDTRA 14050A...
  • Page 28 A noisy clutch may be caused by a number of conditions. Most of these conditions can be corrected only after you have removed the assembly from the vehicle. Start your inspection by noting whether or not the noise occurs when the clutch is engaged or NAVEDTRA 14050A...
  • Page 29 It would be impractical to list every possible clutch problem and its remedy for repair in this training manual. Consult the manufacturer's operation and repair manual before making adjustments to any clutch system NAVEDTRA 14050A...

  • Page 30: Automatic Transmissions

    Whatever the case and regardless of design or construction, all automatic transmissions have the following six basic systems that enable them to function: 1. A torque converter or fluid coupling 2. A hydraulic system 3. A planetary gearset (usually more than one) NAVEDTRA 14050A...
  • Page 31 Roughly 75 percent of the 4L80Es internal parts are interchangeable with a TH400, and the bellhousing bolt pattern and flexplate are the same as the 400, so it bolts up to big- or small-blocks just like normal. Figure 7-8 - 4L80E automatic transmission. NAVEDTRA 14050A...

  • Page 32: Planetary Gears

    This causes the planet pinions to act as idlers, thus driving the output member in the opposite direction (Figure 7-9, View C). In both cases, the output member is turning in the opposite direction of the input member. NAVEDTRA 14050A 7-10...
  • Page 33 Because the turbine member has absorbed the force required to reverse the direction of the clockwise spinning of oil, it now has greater force than is being delivered by the NAVEDTRA 14050A 7-11...

  • Page 34: Hydraulic System Operation

    Beyond the crescent, the gear teeth begin to come together again, forcing the oil out of the pump and into the hydraulic system under pressure. At this point, the oil is delivered to the pressure control system. NAVEDTRA 14050A 7-12...
  • Page 35 ECM that the transmission is in drive. 2.4.4 Drive, Second Gear When the ECM decides the transmission is to be shifted into second gear, it de- energizes the 1-2 shift selonoid. Since this solenoid is normally open, oil exits through NAVEDTRA 14050A 7-13...
  • Page 36 Automatic transmission service can be easily divided into the following three parts: preventive maintenance, troubleshooting, and major overhaul. Before you perform any maintenance or repairs on an automatic transmission, consult the maintenance manual for instructions and proper specifications NAVEDTRA 14050A 7-14...
  • Page 37 When adjusting these linkages, you should strictly adhere to the manufacturer's specifications. If an automatic transmission is being used in severe service, the manufacturer may suggest periodic band adjustment, as shown in Figure 7-12. Always adjust lockup NAVEDTRA 14050A 7-15...
  • Page 38 The draining of the transmission can be accomplished in one of the following three ways: 1. Removing the drain plug 2. Loosening the dipstick tube 3. Removing the oil pan NAVEDTRA 14050A 7-16...
  • Page 39 An engine that is not operating properly will not allow the transmission to function normally NOTE A malfunction may have more than one probable cause. Complete all the tests and inspections for each cause to find the correct cause. NAVEDTRA 14050A 7-17...
  • Page 40 In this step, you will need to recheck the transmission. Give it another road test. Be sure to fully evaluate the transmission and be sure to pay attention to what you fixed to make sure that the problem no longer exists. NAVEDTRA 14050A 7-18...
  • Page 41 3. Check the input (Figure 7-13) and output (Figure 7-14) shaft endplay. This should be checked before disassembly and after reassembly. Record the endplay readings for later reference. Figure 7-13 - Checking input Figure 7-14 - Checking output shaft endplay. shaft endplay. NAVEDTRA 14050A 7-19...
  • Page 42 You should always replace the seal when the pump is serviced. Figure 7-17 - Removing oil Figure 7-16 - Removing oil pump. pump seal. NAVEDTRA 14050A 7-20...
  • Page 43 Look for any worn thrust washers and replace them as required. Check the condition and proper operation of all vacuum or electronic devices connected to the unit. The automotive type of torque converter is usually a welded unit and can NAVEDTRA 14050A 7-21...
  • Page 44 The power flow to the drive wheels is something a construction mechanic needs to understand to enable you to properly troubleshoot and diagnose equipment. When you have mastered the knowledge of these systems, you will become a better NAVEDTRA 14050A 7-22...
  • Page 45 The friction disc facing for normal surface condition The pilot bearing for unusual wear Which of the following practices is recommended to correct a stiff clutch pedal? Oiling the disc facings Riding the clutch Lubricating the clutch linkage Adjusting free travel of the pedal NAVEDTRA 14050A 7-23...
  • Page 46 What results when two members of a planetary gearset rotate together? Reverse Low gearing High gearing Direct drive What means or device within the torque converter allows for shifting without interruption of engine torque application? The turbine The fluid coupling The stator The impeller NAVEDTRA 14050A 7-24...
  • Page 47 Moving the gear selector through all positions several times with the engine running and the brakes applied Letting the unit sit for 10 minutes while the fluid settles Keep adding fluid until all air bubles are removed NAVEDTRA 14050A 7-25...
  • Page 48 Both A and B To disassemble clutch packs When you disassemble an automatic transmission, you must remove what component before removing the valve body? The control valve spacer The vacuum modulator The rear servo The oil pan NAVEDTRA 14050A 7-26...
  • Page 49 Trade Terms Introduced in this Chapter Coupling To join the engine with the transmission Uncouple To separate the engine and transmission NAVEDTRA 14050A 7-27...
  • Page 50 Automatic Transmissions and Transaxles, James Duffy, The Goodheart-Wilcox Company, Inc., 2005. (ISBN: 1-59070-426-6) Manual Drive Trains and Axles, Chris Johanson, James Duffy, The Goodheart-Wilcox Company, Inc., 2004. (ISBN: 1-59070-320-0) Power trains, Fundamentals of Service, Deere and Company, John Deere Inc., 2005. (ISBN: 0-86691-325-4) NAVEDTRA 14050A 7-28...
  • Page 51 Technical Review Committee. Thank you for your assistance. Write: CSFE N7A 3502 Goodspeed St. Port Hueneme, CA 93130 FAX: 805/982-5508 E- mail: CSFE NRTC@navy.mil Rate Course Name Revision Date Chapter Number Page Number(s) Description (Optional) Correction (Optional) Your Name and Address NAVEDTRA 14050A 7-29...
  • Page 52 The last topic covered is troubleshooting differentials, which provides a wide range of exposure to the components of the differential. The drivetrain is the last bastion for a mechanic to be a mechanic, with its gears, yokes, bushings, universal joints, splines, etc. NAVEDTRA 14050A...

  • Page 53: Features Of This Manual

    • The first time a glossary term appears in the text, it is bold and italicized. When your cursor crosses over that word or phrase, a popup box displays with the appropriate definition. NAVEDTRA 14050A...
  • Page 54 When you have completed your review, select anywhere in that area to return to the review question. Try to answer the question again. NAVEDTRA 14050A...
  • Page 55 It is your responsibility as a mechanic to determine the cause, so it is really important that you do not jump to conclusions based on the driver's/ operator's complaint. First determine the source of the noise. Next, if you are sure it is coming from the NAVEDTRA 14050A...
  • Page 56 Remember that the input shaft rotates at engine speed when the clutch is engaged, and the output shaft rotates at driveshaft speed. Make a note of the gear the vibration occurs at, and note whether it occurs only in high range or only in low. Make NAVEDTRA 14050A...
  • Page 57 In contrast, if internal parts of a shift linkage are bent or sticking, the transmission must be removed and disassembled to make repairs. Bad synchronizers, which can be responsible for hard shifting, or clutch problems wil require transmission removal. Misalignment problems may require transmission NAVEDTRA 14050A...
  • Page 58 A transmission can also become locked in gear when drive gear teeth are broken. The teeth can jam together and be locked by bits of metal from chipped teeth. Diagnosis chart. Refer to the quick reference diagnosis chart (Figure 8-2). NAVEDTRA 14050A...
  • Page 59 Drain and fill with correct lubricant Engine rpm too high Set to correct idle rpm Driver not waiting long enough after Instruct driver depressing clutch Sticking clutch pilot bearing Replace pilot bearing Figure 8-2 - Transmission quick reference diagnosis chart. NAVEDTRA 14050A...
  • Page 60 • Fasteners and gaskets. Use a wrench to check the torque on bolts and plugs, paying special attention to those on PTO covers/flanges and the rear bearing cover assembly. Look for oil leakage at all gasket mating surfaces. NAVEDTRA 14050A...
  • Page 61 Output shaft assembly. (11) Pry upward on the output shaft to check radial play in the mainshaft rear bearing. Check the splines on the output shaft (12) for wear from movement and chucking action of the U-joint yokes. Figure 8-3 - Inspection points on standard transmission. 8-10 NAVEDTRA 14050A...
  • Page 62 O-ring or gasket has not failed. Hydraulic thread sealant applied to the threads can sometimes cure this type of leak. Inspect the rear bearing cover assembly bolts for tightness. These fasteners should be torqued to specification. Thread sealant is required to seal the fastener 8-11 NAVEDTRA 14050A...
  • Page 63 Inspect the oil drain plug and oil fill plug for leakage. The oil drain plug and oil fill plug should be torqued to specification. Always check for a plugged transmission breather when identifying the cause of a transmission oil leak. When transmission oil is raised from cold to operating 8-12 NAVEDTRA 14050A...
  • Page 64 So be sure to check all mounting bolts on the engine, transmission, and differentials before road testing the vehicle. Also, check the propeller shafts and U-joints for evidence of wear or looseness. 8-13 NAVEDTRA 14050A...
  • Page 65 When this happens, the transmission slips out of gear. Occasionally, a transmission slips out of gear because the driver does not fully engage the gear when moving the lever. However, when a transmission slips out of gear fairly often, it should be replaced. 8-14 NAVEDTRA 14050A...
  • Page 66 Figure 8-6 - Transmission jack. Secure the vehicle on a hoist or set of jack stands. A hoist is better because it allows you to stand while working. Remove the transmission drain plug and drain the oil into a catch pan. 8-15 NAVEDTRA 14050A...
  • Page 67 Slide the transmission straight back, holding it in alignment with the engine (Figure 8-8). You may have to wiggle the transmission slightly to free it from the engine. Clean the outside of the transmission and take it to a workbench. 8-16 NAVEDTRA 14050A...
  • Page 68 Going to the front of the transmission, remove the front bearing cover and any snap rings. Carefully pry the input shaft and gear forward far enough to free the main output shaft. 8-17 NAVEDTRA 14050A...
  • Page 69 Replace parts as needed. View A shows all the components of the assembly. View B shows basic synchronizer components. View C shows checking shift forks and synchronizers for wear. View D illustrates inspect ridges inside the blocking ring. 8-18 NAVEDTRA 14050A...
  • Page 70 Shift Fork Together Measuring Fork-To-Groove Clearance With Feeler Gauge I n spect Fine Rldges Check Shift Forks Synchronizer I n spect Synchronizer S eeve Teeth Blocking Ring Figure 8-11 -I n specting synchron i z er assembly. 8-19 NAVEDTRA 14050A...
  • Page 71 Again, refer to the service manual for detailed Figure 8-13 - Removing bearings with procedures for reassembly. puller. The service manual will usually have exploded views of the transmission (Figure 8-14) and assemblies (Figure 8-15). They 8-20 NAVEDTRA 14050A...
  • Page 72 Make sure the transmission shifts properly before installing it. This will definitely save you from having to remove the transmission later when problems are discovered. While the transmission is removed from the vehicle, it would be recommended to disassemble and inspect the clutch. 8-21 NAVEDTRA 14050A...
  • Page 73 5-sp eed transmission. Figure 8 1 4 Exploded view f AVEDTRA 1 4050A...
  • Page 74 CAUTION Do not use the transmission bolts to draw the transmission into the clutch housing. The transmission input shaft could be smashed into the crankshaft pilot bearing. Serious component damage may result. NAVEDTRA 14050A 8-23...
  • Page 75 Snap ring Clutch hub 103. Transmission case sleeve Blocking ring Clutch sleeve 104. Transmission case Synchronizer spring Snap ring Synchronizer blocking ring Shift plate Clutch hub Speed gear Figure 8-14 - Exploded view of a 5-speed transmission (cont.). NAVEDTRA 14050A 8-24...
  • Page 76 14. Reverse lever pivot bolt 38. Third - fourth synchronizer 28. First - second synchronizer insert 15. First - second synchronizer insert spring (2) insert (3) 29. Second gear Figure 8-15 - Exploded view of a mainshaft assembly. NAVEDTRA 14050A 8-25...
  • Page 77 Figure 8-16 - Installing needle bearings. Figure 8-17 - Using a feeler flat gauge to measure clearance between mating parts. NAVEDTRA 14050A 8-26...
  • Page 78 Carefully road test the vehicle, making sure the transmission and clutch operate properly. If any problems are detected, correct them before releasing the vehicle. Make any other adjustments as needed and recheck the oil level. NAVEDTRA 14050A 8-27...
  • Page 79 The front axle declutch is used to option-drive to the front axle when negotiating steep grades or slippery or rough terrain. Both the PTO and front axle drive declutch are driver engaged by dedicated shift levers. NAVEDTRA 14050A 8-28...
  • Page 80 Although it is relatively small, the transfer case can develop problems that affect the entire drive train. Accurately determining the source of the problem is the first step in repairing a transfer case. Figure 8-21 illustrates some of the components that can develop problems in a typical transfer case. NAVEDTRA 14050A 8-29...
  • Page 81 Prob l e ms Lever TransferI n dicator Retainer Wear Switch Open Or Shorted Leaking Gasket Reduction Gear Housing Warpage Or Damage Figure 8-21 -Exploded view of a gear-type transfer case showing components that can develop problems. NAVEDTRA 1 4050A 8-30...
  • Page 82 Transfer case failure causing a no-drive condition in all gears is usually caused by stripped gears or splines, a broken chain, a broken shaft, or a viscous coupling that has lost its fluid. Generally, a transfer case must be removed from the vehicle to repair these defects. NAVEDTRA 14050A 8-31...
  • Page 83 In some cases, the linkage simply needs lubrication. Figure 8-23 shows shift linkage adjustment. If the linkage is okay, the problem may be caused by bent or damaged shift forks inside the transfer case. NAVEDTRA 14050A 8-32...
  • Page 84 If the viscous coupling has failed, check the different front and rear axle ratios, which may have caused it to fail. Refer to Figure 8-24 for quick reference to troubleshooting. NAVEDTRA 14050A 8-33...
  • Page 85 Repair or replace transfer case. Vehicle wanders when driving Improperly matched tire size. Use a matched set of tires. straight ahead. Uneven tire pressure. Adjust air pressure to recommended levels. Figure 8-24 - Transfer case quick reference troubleshooting guide. NAVEDTRA 14050A 8-34...
  • Page 86 During removal, the transfer case must be removed away from the transmission until it clears the output shaft. As you lower the transfer case, make sure it does not catch on NAVEDTRA 14050A 8-35...
  • Page 87 After accessing the internal parts, remove any snap rings that hold the transfer case gears to the shaft or secure the shafts to the housing. Then remove the internal parts as NAVEDTRA 14050A 8-36...
  • Page 88 All shafts, sliding gears, and planetary gears, if used, should be removed at this time. Refer to the service manual for detailed disassembly procedures for your particular transfer case. Figure 8-26 - Prying apart a transfer case housing. Figure 8-27 - Disassembly of a one-piece transfer case. NAVEDTRA 14050A 8-37...
  • Page 89 Additionally, check all bushings and seals for wear. All internal transfer case parts should be inspected for wear and damage. Examine all shaft Figure 8-29 - Check planetary gear bearings, needle beatings, shift assembly. NAVEDTRA 14050A 8-38...
  • Page 90 Figure 8-31 - Checking shift fork for wear. If the transfer case uses a differential assembly or a viscous coupling, it should be checked for wear and damage. Always follow the inspection procedures outlined in the factory service manual. NAVEDTRA 14050A 8-39...
  • Page 91 If not, you will just have to disassemble and reassemble correctly. Reassembly procedures may vary with the transfer cases you will overhaul. The following procedures will serve as a general guide to reassembly. NAVEDTRA 14050A 8-40...
  • Page 92 69. Snap ring 23. Washer and retainer 45. Spacer 70. Rear cover gasket 24. Shift fork 46. Idler shaft bearing 71. Rear cover and bearing 47. Idler shaft Figure 8-33 - Exploded view of a typical one-piece transfer case. NAVEDTRA 14050A 8-41...
  • Page 93 Figure 8- 36. Next, install the snap rings that hold the chain and shafts in Figure 8-34 - Reassembly of internal place. components. Figure 8-35 - Reinstalling drive chain and sprockets. NAVEDTRA 14050A 8-42...
  • Page 94 Figure 8-37 - Recheck all components endplay should be measured. If before installing rear housing. endplay is incorrect, the rear half of the housing or the bearing retainer must be removed, and thicker or thinner thrust washers must be installed. NAVEDTRA 14050A 8-43...
  • Page 95 Make sure the drive shaft yokes will still turn after the transfer case is tightened. 3. If necessary, install the crossmember and rear engine mount, then remove the transmission jack. 4. Reconnect both drive shafts to the transfer case output yokes. NAVEDTRA 14050A 8-44...
  • Page 96 3. Top mount-is usually found mounted to the top of an auxiliary transmission. 4. Countershaft-is mounted behind the transmission and when used replaces the bearing cap located at the rear of one countershaft on a twin-countershaft transmission. NAVEDTRA 14050A 8-45...
  • Page 97 Most PTOs feature simple designs and rugged construction. Care should be taken to properly mount a PTO. Setting backlash to specification is critical; this operation is performed by setting the gasket thickness at the PTO mounting flange. Contaminated transmission oil can damage a PTO, so regular maintenance is important. NAVEDTRA 14050A 8-46...

  • Page 98: Pto Maintenance

    (or driven unit). Drivelines must be in phase, that is, the yoke ears on the PTO and pump shafts must be in alignment; Figure 8-41 provides a quick reference for troubleshooting a power takeoff. NAVEDTRA 14050A 8-47...
  • Page 99 Replace defective gears. Worn bearings. Replace defective bearings. Worn shaft splines Replace shafts. Slipping out of gear. Gears partially engaged. Correctly adjust shift linkage. Weakened poppet springs. Replace springs. Figure 8-41 - Power takeoff quick reference diagnosis. NAVEDTRA 14050A 8-48...
  • Page 100 2. Yokes 3. Slip splines 4. Propeller shafts The propeller shafts have a tubular construction designed to sustain high torque loads and be light in weight. Figure 8-43 shows the components of a typical heavy-duty truck driveshaft. NAVEDTRA 14050A 8-49...
  • Page 101 45). For example, the transmission yoke is angled 3 degrees down from horizontal plane, while the rear axle pinion flange is angled up at 12 degrees. Providing that the U- joint angles of this propeller shaft remain equal, the shaft will run vibration free. NAVEDTRA 14050A 8-50...
  • Page 102 Unequal U-joint working angles can cause vibrations and contribute to U-joint transmission, and differential problems. Ideally, the operating angles on each end of a driveshaft should be equal or within 1 degree of each other and have a 3-degree- NAVEDTRA 14050A 8-51...
  • Page 103 At high speeds, balance becomes more critical. This is why manufacturers limit tube length. For example, at 3,000 rpm the length of any single driveshaft section, measured between the centerline of the U-joints at either end, should not usually exceed 70 inches. NAVEDTRA 14050A 8-52...
  • Page 104 Figure 8-50. If a driveshaft is assembled one spline out, the driveshaft is out of phase and the result can be a significant vibration. There should be opposing alignment arrows stamped on the slip yoke and on the tube shaft so you NAVEDTRA 14050A 8-53...

  • Page 105: Driveshaft Inspection

    Anything adhering to the driveshaft has the potential to unbalance it. 6. Check the hanger bearing visually, making sure it is mounted securely. Check for damaged seals, rubber insulator failure, or lubricant leaking from the bearing. NAVEDTRA 14050A 8-54...
  • Page 106 This flushes contaminants out of the bearings and helps ensure that all four have taken grease. The U-joint is properly greased when evidence of purged grease is seen at all four bearing trunnion seals. NAVEDTRA 14050A 8-55...
  • Page 107 However, when replacing a support bearing assembly, fill the entire cavity around the bearing with chassis grease to shield the bearing from water, salt, and other contaminants. You should put enough grease to fill the cavity to the edge of the slinger around the bearing. NAVEDTRA 14050A 8-56...
  • Page 108 Gently tap on the outside of the yoke with a light hammer if the bearing cup does not loosen when initial pressure is applied. After the bearing cup has been exposed above the bore, it can usually NAVEDTRA 14050A 8-57...
  • Page 109 Hold the shaft firmly when tapping the flanges free. When separated, compress the driveshaft by forcing it inboard and lower the assembly to the floor. NAVEDTRA 14050A 8-58...
  • Page 110 Galling is commonly found on trunnion ends. • Spalling (surface fatigue) occurs when chips, scales, or flakes of metal break off due to fatigue rather than wear. Spalling is usually found on splines and U-joint trunnion races. NAVEDTRA 14050A 8-59...
  • Page 111 If the bearing cap binds in the yoke bore, gently tap with a ball peen hammer in the center of the bearing cap. Do not tap the outer edges of the bearing cap because this could damage either the bearing cup or the yoke. NAVEDTRA 14050A 8-60...

  • Page 112: Driveshaft Installation

    Then raise the driveshaft slightly and move it to one side of the yoke so that a trunnion protrudes through it. In this position, you can place a bearing cup over the protruding trunnion, align it, and press it home by hand into the yoke bore. NAVEDTRA 14050A 8-61...
  • Page 113 Note any irregularities and at what engine or road speeds they occur. If the problem is noticeable only when pulling a trailer, try coupling to a different trailer to see if the problem persists. NAVEDTRA 14050A 8-62...
  • Page 114 CAUTION Use small tack welds to attach weights. Larger welds can create another imbalance or, worse, distort driveshaft tubing. NAVEDTRA 14050A 8-63...
  • Page 115 U-joint cap removed, or on a flat surface of the main transmission parallel to the output yoke lug plane. Record your readings on a sketch of the driveline. Figure 8-56 - Digital inclinometer. NAVEDTRA 14050A 8-64...
  • Page 116 Figure 8-58. Up to this point, you have not recorded any U-joint operating angles in the drawing, just the inclination of the components. NAVEDTRA 14050A 8-65...
  • Page 117 On some vehicles with tandem drive axles, shimming of longitudinal torque rods can be used to adjust the drive carrier operating angle. Longitudinal torque rod shims fractionally rotate the drive axle pinion that alters the U-joint operating angle. A longer or NAVEDTRA 14050A 8-66...
  • Page 118 4.9.2 and Alignment Not only must the driveshaft be straight but the yokes attached to the transmission, auxiliary transmission, and drive axles must also be true and straight and in alignment with the shafts to which they are attached. NAVEDTRA 14050A 8-67...
  • Page 119 Then, if the yoke is a half-round type, place a protractor with a magnetic base in a vertical position across the mechanical surfaces of the yoke (Figure 8-62). The protractor dial should read 90 degrees minus the inclination of the engine/transmission plane. NAVEDTRA 14050A 8-68...
  • Page 120 In some applications, an auxiliary power unit, such as a pump, can be directly mounted to the power takeoff (PTO) assembly (Figure 8-65, View A). However, it is more common to locate PTO driven units remotely and drive them using a driveshaft (Figure 8-65, View B). NAVEDTRA 14050A 8-69...
  • Page 121 Realign to proper running angle for U-joint and driveshaft size minimum 1 degree; torque bearing retention method to specification. Slip spline wear Improper lubrication Lubricate slip sp[line according to • specifications. seizure • galling Figure 8-64 - Driveshaft Troubleshooting Guide NAVEDTRA 14050A 8-70...
  • Page 122 Try to make sure the axle housing is horizontally close to level. 3. Remove the drain plug from the bottom of the axle housing and drain the lubricant from the assembly. Dispose of the lube properly. NAVEDTRA 14050A 8-71...
  • Page 123 11. Back off the top two carrier-to-housing fasteners, leaving them Figure 8-67 - Support the differential attached to the assembly. carrier with a hydraulic jack. The fasteners will hold the carrier in the housing. NAVEDTRA 14050A 8-72...
  • Page 124 4. Mark one carrier leg and bearing cap for the purpose of correctly matching the parts when the carrier is reassembled. A center punch and hammer can be used to mark these components (Figure 8-69). Avoid using paint because it may contaminate when placed back in service. NAVEDTRA 14050A 8-73...
  • Page 125 Figure 8-70 - Removing the cotter key and lock plate. 6. Remove the capscrews and washers that hold the two bearing caps on the carrier. Each cap is held in position by a pair of capscrews and washers. When NAVEDTRA 14050A 8-74...
  • Page 126 The purpose of these marks is to match the plain half and flange half correctly when reassembling the carrier. Figure 8-72 - Disassemble the differential and crown gear. 2. Remove all hardware that holds the case halves together. NAVEDTRA 14050A 8-75...
  • Page 127 (Figure 8- 75). Remove the retaining nut from the drive pinion. Then remove the yoke or flange bar. NAVEDTRA 14050A 8-76...
  • Page 128 Record the dimension. You will need it to calculate the depth of the drive pinion in Figure 8 - 77 - Removing the drive pinion the carrier when the gearset is installed. and bearing cage. NAVEDTRA 14050A 8-77...
  • Page 129 Remove the spigot bearing from the drive pinion with a bearing puller. Differential Carrier Reassembly The reassembly procedure is essentially a reversal of the disassembly procedure. The procedure outlined is general. Always refer to the service manual for the proper and detailed procedures for the unit being overhauled. NAVEDTRA 14050A 8-78...
  • Page 130 Install the drive pinion into the bearing cage. Install the bearing spacer(s) onto the pinion shaft against the inner Figure 8-80 - Drive pinion assembly. bearing cone (Figure 8- 80). NAVEDTRA 14050A 8-79...
  • Page 131 Install the input yoke or flange onto the drive pinion. Figure 8-82 - Cover and seal assembly, The yoke or flange must be gasket and bearing cage. against the outer bearing NAVEDTRA 14050A 8-80...
  • Page 132 1 minute and check for gaps between the back surface of the ring gear and the case flange using a 0.003-inch thickness gauge (Figure 8-84, View B). NAVEDTRA 14050A 8-81...
  • Page 133 Install hardware into the case halves. The distance between fasteners must be equal. Tighten the fasteners to the correct torque value in a pattern opposite each other. Check the differential rolling resistance of the differential gears. NAVEDTRA 14050A 8-82...
  • Page 134 Apply axle lubricant on the inner diameter of the bearing cups and onto both bearing cones that are assembled on the case halves. Apply a suitable adhesive in the bearing bores of the carrier legs and bearing caps. NAVEDTRA 14050A 8-83...
  • Page 135 Figure 8-89 - Installation of bearing caps Adjust preload of using match marks. differential bearing. Check runout of ring gear. Adjust backlash of ring gear. Check and adjust tooth contact pattern. NAVEDTRA 14050A 8-84...
  • Page 136 Carefully push the carrier into position. Tighten the four fasteners two or three turns each in a pattern opposite each other. Figure 8-91 - Installing the gaskets and axle shafts into the axle housing and NAVEDTRA 14050A 8-85 carrier.
  • Page 137 Measure the input shaft end play again with a dial indicator. If the endplay is still incorrect, repeat Steps 3-7. With the endplay correct, seal the shim pack to prevent lube leakage. Then torque the input shaft nut and cover capscrews to the correct value. NAVEDTRA 14050A 8-86...
  • Page 138 Adjust the dial indicator so that the plunger is against the tooth surface at a right angle. Adjust the dial indicator to zero, making sure the plunger is loaded through at least one revolution. Hold the drive pinion in position. NAVEDTRA 14050A 8-87...
  • Page 139 The tooth contact pattern consists of the lengthwise bearing (along the tooth of the ring gear) and the profile bearing (up and down the tooth). Figure 8-96 shows crown gear tooth nomenclature. Figure 8-94 - Adjustments to increase backlash. NAVEDTRA 14050A 8-88...
  • Page 140 Figure 8-95 - Adjustments to decrease backlash. Figure 8-96 - Crown gear tooth nomenclature. NAVEDTRA 14050A 8-89...
  • Page 141 (Figure 8-99). The more use a gear has had, the more the line becomes the dominant characteristic of the pattern. Figure 8-98 - Correct tooth contact pattern for new gearing. NAVEDTRA 14050A 8-90...
  • Page 142 (Figure 8-100). Pinion position is determined by the size of the pinion bearing cage shim pack. It controls contact on the tooth depth of the gear tooth (Figure 8-101). Figure 8-100 - Two incorrect patterns during adjust pinion position. NAVEDTRA 14050A 8-91...
  • Page 143 The bearing and axle are held in the housing by an axle retainer plate mounted on the outer end of the rear axle housing. The retainer Figure 8-102 - Ball bearing semi-floating axle. NAVEDTRA 14050A 8-92...
  • Page 144 The other method has the wheel hub (axle and flange, in this case) solidly mounted to the axle. Figure 8-104 - Tapered roller bearing semi- floating axle. NAVEDTRA 14050A 8-93...
  • Page 145 Figure 8-106 - Typical heavy-duty full- servicing. The axles are easily floating axle. removed when the equipment needs to be towed in a non-run NAVEDTRA 14050A 8-94...

  • Page 146: Service And Maintenance

    Although some failures are caused by improper installation of components, mechanics need to make themselves aware of correct methods and ensure that the proper replacement parts and tools are used to assemble the components. NAVEDTRA 14050A 8-95...
  • Page 147 Using the correct viscosity will be operating- temperature dependent, and should be adhered to. Figure 8-107 shows the proper grade of lubricant for a given operating temperature. NAVEDTRA 14050A 8-96...
  • Page 148 4. Using a viscosity that is not suitable for the application temperatures may result in a lubrication film breakdown, leading to severe scoring and galling. The internal gears will often be blackened from the heat. NAVEDTRA 14050A 8-97...
  • Page 149 The average temperature of lubricants in axles is between 160°F and 220°F in summer months. Operating equipment with temperatures above 200°F causes the oil to oxidize at a higher rate, depleting the additives that give NAVEDTRA 14050A 8-98...
  • Page 150 NAVEDTRA 14050A 8-99...
  • Page 151 Even though you have the repair manual for your vehicle, before ordering any parts for your transmission, what should you check to be sure it is the correct transmission? Vehicle identification tag Parts manual Vehicle purchase order Transmission identification tag NAVEDTRA 14050A 8-100...
  • Page 152 Use a special needle bearing holder Get someone else to do it (True or False) When installing the standard transmission, one helpful action is to use the transmission bolts to draw the transmission into the clutch housing. True False NAVEDTRA 14050A 8-101...
  • Page 153 Oil coupling Viscous bearing Viscous coupling What is the first step when removing the transfer case for repairs? Raise the vehicle high enough to stand underneath Disconnect the negative battery cable Remove the support brackets Drain the oil NAVEDTRA 14050A 8-102...
  • Page 154 Of the six basic types of power takeoffs referred to in the chapter, which is the most common type found on trucks? Split shaft Top mount Countershaft Side mount What term refers to the space between meshing surfaces of the gears in the gearbox devices? Whiplash Backlash Gear clash Gear conflict NAVEDTRA 14050A 8-103...
  • Page 155 What is the typical minimum OEM specification, in inches, when you are inspecting the looseness across the U-joint bearing caps and trunnions? .0006 0.006 0.060 0.600 Heavy-duty driveshafts typically use what type of grease? Silicone-based extreme pressure Water-soluble Bearing Lithium soap-based extreme pressure NAVEDTRA 14050A 8-104...
  • Page 156 Torque them down with a wrench Turn them in first by hand Add grease to the threads Add the retainer clips An unbalanced driveline causes transverse and bending the driveshaft. movements, vibrations action, movements rotation, action vibrations, movements NAVEDTRA 14050A 8-105...
  • Page 157 True False As you go through the steps to remove the differential, as a safety precaution, you should not remove the axle retaining nuts until you have loosened which components? Capscrews Flanges Tapered spring dowels Axle shafts NAVEDTRA 14050A 8-106...
  • Page 158 What is the proper procedure for the fasteners after installing the hardware into the case halves of the differential? Tighten in a clockwise pattern Tighten every other counter clockwise Tighten in an opposite pattern Tighten in a staggered pattern NAVEDTRA 14050A 8-107...
  • Page 159 C-lock axle because of the shape of the locking clip? Tapered roller bearing Roller bearing version Encased semi-floating Pinion version The full-floating axle will typically be found on what type of vehicle/equipment? Sedans Small pickups Large, slow moving off-road Track equipment NAVEDTRA 14050A 8-108...
  • Page 160 What is the recommended lubricant to use in drive axles? API-GL-1 API-GL-2 API-GL-4 API-GL-5 For approximately how many minutes should you wait before checking the oil level in the differential drive axle after operation? NAVEDTRA 14050A 8-109...
  • Page 161 Wilcox Company, Inc., 2004, (ISBN: 1-59070-320-0) Heavy Duty Truck Systems 4 Edition, Sean Bennett and Ian Andrew Norman, Delmar Cengage Learning, 2006, (ISBN 1-4018-7064-3) Automotive Technology, A Systems Approach, 4 Edition, Jack Erjavec, Thomas, Delmar Learning, 2005. (ISBN: 1-4018-4831-1) NAVEDTRA 14050A 8-110...
  • Page 162 Technical Review Committee. Thank you for your assistance. Write: CSFE N7A 3502 Goodspeed St. Port Hueneme, CA 93130 FAX: 805/982-5508 E- mail: CSFE_NRTC@navy.mil Rate_ Course Name Revision Date Chapter Number Page Number(s) Description (Optional) Correction (Optional) Your Name and Address NAVEDTRA 14050A 8-111...
  • Page 163 The final topic discusses track alignment along with track components and adjustment. Objectives When you have completed this chapter, you will be able to do the following: 1. Identify types of steering geometric angles. 2. Understand how to adjust front-end wheel alignment. NAVEDTRA 14050A...
  • Page 164 • Audio and video clips are included in the text, with an italicized instruction telling you where to click to activate it. NAVEDTRA 14050A...
  • Page 165 When you have completed your review, select anywhere in that area to return to the review question. Try to answer the question again. NAVEDTRA 14050A...
  • Page 166 Bending an axle can damage the structural integrity of Figure 9-2 - Positive and negative camber. the beam, increase the risk of NAVEDTRA 14050A...

  • Page 167: Caster Angle

    Like the furniture caster, the tire finds the path of least resistance by following behind the steering axis line. This tendency of the wheels to continue to move in a straight line is called tracking. NAVEDTRA 14050A...
  • Page 168 Wheel pull is the tendency of the vehicle to drift to one side when the driver releases the steering wheel when the vehicle is moving. A large Figure 9-5 - Negative caster. difference in caster between the NAVEDTRA 14050A...
  • Page 169 Too much toe-in produces scuffing, or a featheredge, along the inner edges of the tires. Excessive toe-out produces a similar wear pattern along the NAVEDTRA 14050A...
  • Page 170 After measuring toe, you can use the following procedure to adjust toe angle: Use the steering wheel to turn the steering gear to the exact mid-position (overcenter). Loosen the clamping bolts on both tie-rod ends. Raise the weight off the axles. NAVEDTRA 14050A...

  • Page 171: Turning Radius

    (Figure 9-8), and tighten the jam nut. Repeat the same procedure on the left extreme turn and set the left steering knuckle Figure 9-8 - Stop screw determines the stop screw. maximum turning angle. NAVEDTRA 14050A...
  • Page 172 In trucks, the Ackerman steering error has to be smallest at low turning angles, where the most steering corrections are made and at the highest speeds. NAVEDTRA 14050A 9-10...
  • Page 173 Figure 9-11 - In a toe-out condition on and replace any that are turns, the inside wheel turns at a greater bent. Do not attempt to distance than the outside wheel. straighten them. NAVEDTRA 14050A 9-11...
  • Page 174 The distance on each side should be within Y inch of each other. If not, the axle must be aligned. Figure 9-13 - Typical incorrect tracking of tandem-axle vehicles. NAVEDTRA 14050A 9-12...
  • Page 175 Axle offset is expressed in degrees based on variance with the geometric driving axis, or thrust angle. Thrust angle is the angle between the longitudinal center plane and the geometrical axis. Figure 9-14 - Incorrect tracking of trailers. NAVEDTRA 14050A 9-13...

  • Page 176: Adjusting Wheel Alignment

    Never place the lifting pad under the floor pan or under steering and suspension components. These areas may look strong enough to hold a lot of weight but are not. NAVEDTRA 14050A 9-14...
  • Page 177 • Do not allow anyone to remain in a vehicle when it is being raised. • Make certain you know how to operate the equipment and know its limitations. • Never overload a lift, hoist, or jack. NAVEDTRA 14050A 9-15...
  • Page 178 This system is simpler to set up than older systems. Alignment wrenches. Various specially designed wrenches are needed to perform alignments. Alignment wrenches are specially shaped wrenches. These wrenches are NAVEDTRA 14050A 9-16...
  • Page 179 Most inner tie-rod tools can also be used to install a new inner tie rod. Lever-type adjusting tool. To move the control arms on various vehicles, a lever-type adjusting tool is needed. The tool is typically attached to the control arm and the frame. NAVEDTRA 14050A 9-17...
  • Page 180 The spot weld cutter is used with an electric or air-powered drill. • Rotary Cutter. When a suspension part must be moved for alignment, the original mounting holes may be large enough to permit the necessary movement. NAVEDTRA 14050A 9-18...

  • Page 181: Alignment Procedures

    On occasion, the problem may be something that an alignment will not fix. Worn parts or unbalanced tires may cause what the operator perceives as a wheel alignment problem. This is particularly true of NAVEDTRA 14050A 9-19...
  • Page 182 Sometimes it is necessary to pry on parts using a pry bar. On some vehicles, the tie rods will be looser when the wheels are on the ground. Check your service manual for recommendations. NAVEDTRA 14050A 9-20...
  • Page 183 If the setback varies by more than 1 inch between sides, a suspension part is bent. Make all necessary repairs before continuing with the alignment. NAVEDTRA 14050A 9-21...
  • Page 184 Tires) Lack of Rotation Feathered Edge Wear Excessive Toe Angle (Bias Tire) Excessive Camber Angle Uneven Wear (One Side Tread) Excessive Toe Angle (Radial Tire) Out of Spec. Turning Angle (Toe out on turns) Figure -Tread wear. 9-16 NAVEDTRA 14050A...
  • Page 185 On most machines, this is an automatic process once the heads have been compensated. On older alignment machines using lighted heads, the front camber and toe will be shown by the position NAVEDTRA 14050A 9-23...
  • Page 186 Many trucks use a solid or twin I-beam front axle, and there are no provisions for adjusting caster and camber. The only way to adjust caster and camber on these trucks is to replace the upper ball joint bushing with a special eccentric bushing, or sleeve. NAVEDTRA 14050A 9-24...
  • Page 187 Caster specifications are based on vehicle design load (no load), which will usually result in a level frame. If the frame is not level when alignment checks are made, this must be factored in the caster measurement. With the vehicle on a smooth, level NAVEDTRA 14050A 9-25...
  • Page 188 Make sure you determine whether the caster angle you measure is positive or negative. The original orientation of the protractor must be remembered Figure 9-18 - Placement of a protractor to when determining the measure caster. direction of the caster NAVEDTRA 14050A 9-26...
  • Page 189 Be sure that the tires contact the center of the turntables, as shown in Figure 9-21. Remove the lock pins that hold the turntables in a Figure 9-21 - Basic wheel alignment fixed position. equipment. NAVEDTRA 14050A 9-27...
  • Page 190 The caster is positive if the bubble is toward the positive sign and negative if the bubble is toward the negative sign. Repeat this procedure on the opposite side of the vehicle. NAVEDTRA 14050A 9-28...
  • Page 191 Measure the caster again. Changing shims does not always produce the exact caster change desired. In most cases, caster angle should not change significantly when a load is added to the vehicle. If steering difficulties persist, caster should be rechecked with the vehicle loaded. NAVEDTRA 14050A 9-29...
  • Page 192 Adjust toe by turning the sleeves or rods to obtain exactly half the needed toe on each wheel. If the toe is not divided exactly, the steering wheel will not be straight. Some NAVEDTRA 14050A 9-30...
  • Page 193 Once both tires are straight, retighten the adjuster locknuts. Lower the vehicle and road test to determine whether the steering wheel is straight. If the steering wheel is still not centered, repeat the centering procedure as needed. NAVEDTRA 14050A 9-31...
  • Page 194 The SAI angle also keeps the vehicle weight on the inner wheel bearing, eliminating the need for excessive camber, which would wear the tire. NAVEDTRA 14050A 9-32...
  • Page 195 Electronically controlled steering systems can fail and provide too much or too little power assist. This can cause hard steering at low speeds or road wander at cruising speeds. This could be mistaken for incorrect caster NAVEDTRA 14050A 9-33...
  • Page 196 This is called caster or camber split. Very little split is needed to compensate for road crown. In most cases, � ° is sufficient. Too much compensation could cause the vehicle to pull left on roads with no road crown. NAVEDTRA 14050A 9-34...

  • Page 197: Track Alignment

    There are actually a number of components that form the complete track system. The drive sprocket, front idler, track rollers, tension mechanism, roller guards, and the frame are all required to make up a track and undercarriage system. NAVEDTRA 14050A 9-35...
  • Page 198 Before attempting any maintenance or repairs to a track and undercarriage system, always refer to the manufacturer's technical documentation or service manual. Figure 9-28 - Master pin. NAVEDTRA 14050A 9-36...
  • Page 199 Clearance between the pins and bushings is minimal, providing only enough clearance for lubrication. In the case of a sealed track, the seal fits over the pin against the track link before installing another link. NAVEDTRA 14050A 9-37...
  • Page 200 Figure 9-30 - Track link. Figure 9-31 - Lubricated track. NAVEDTRA 14050A 9-38...

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