MCi Crusader II 1989 Maintenance Manual page 42

Date
1-1-89 .
Page 2-14
MC-9 MAINTENANCE MANUAL
WARNING: Using wrong weldlng proce-
dures or welding at locations other than the
three areas permitted by Rockwell will make
the heat-treated component weak. A weak
component wlll cause poor or unsafe oper-
ation of the axle and early failure. The fol-
lowing procedure must be used.
WELDING PROCEDURE
1. Drain the lubricant from the axle assembly.
2. Remove the axle shafts and differential carrier from the
axle housing.
3. Clear the damaged area inside and outside the housing.
Cleaning solvent can be used.
WARNING: Be careful when using a clean-
ing solvent. Follow the solvent manufac-
turer's instructions for safe use to prevent
injury.
4. Grind the damaged weld to the base metal.
5. Warm the complete axle housing to a temperature of
70°F-80°F (21 °C-27°C) or higher.
6. Before you start welding, heat the damaged area to be
repaired to approximately 300°F (149°C).
7. Use a 70,000 psi tensile weld material and the correct
voltage and amperage for the diameter weld rod used. Exam-
ples of weld rods that can be used are E-7018 or ER-70S-3.
CAUTION: If the E-7018 weld rod is used,
the rod must be kept dry. Electrodes that
are not stored in the correct sealed con-
tainers must be heated at 700° F (371 "C) for
one hour before weldlng. Wet electrodes
must be dried at 180°F (82°C) for one to
two hours and then heated at 700° F (371
°
C)
for one hour before welding.
8. Fill in the Weld Gap as follows:
CAUTION: Do not connect the ground
cable at any point on the axle assembly that
will put a bearing q_etween the ground cable
and weld area. If a bearing is between the
ground cable and weld, the bearing will be
damaged because of electricity arcing. A
good locatlon to connect the ground cable
is the spring mounting pad of the housing.
a. The snorkel weld must be a .375 inch (9.5 mm) fillet
b. The opening in cover welds must be filled level with the
old weld.
c. The opening in seam welds must be ground out to 70%
of the wall thickness. The wall thickness can be measured atthe
carrier opening of housing,.
d. Clean the new weld area. Carefully remove all the
rough weld material.
e. Install the differential carrier and axle shafts.
f.
Fill the axle assembly with the correct amount of lubri-
cant See Section 10 (Lubrication) of this manual.
NOTE: To weld brackets or other compo-
nents to the axle housing, use the proce-
dure in Rockwell Technical Service Aid,
TSA-2-95.
REPLACING GASKET AND SEALS
At the time of axle or carrier repair, all gaskets, oil seals or ·
grease seals should be replaced.
Silicone gasket material is used at mating surfaces of the
carrier housing and the axle housing. When carrier assembly is
being re-installed in the axle:
1. Remove all old gasket material from both surfaces (Figure
2-35).
2. Clean the surfaces where silicone gasket material will be
applied. Remove all oil, grease, dirt and moisture.
3. Dry both surfaces.
4. Apply a ¼-inch-diameter continuous bead of the silicone
gasket material around one surface. Also apply the gasket
material around the edge of all fastener holes in that surface
(Figure 2-35).
REMOVE OLD -
GASKET MATERIAL
\\61
i
~ ..
-
'"--.i"--
c..::-: -tr,'
~•-""-
Housing and Carrier Shown
Figure 2-35. Replacing Silcone Gasket.
CAUTION: The amount of silicone gasket
material applied must not exceed a 1/,-inch-
dlameter bead. Too much gasket material
can block lubrication passages.
5. Assemble the components immediately to permit the sil-
icone gasket material to compress evenly between the parts.
Tighten fasteners to the required torque value for that size
fastener. See Torque Chart later in this section.
6. Wait 20 minutes before the assembly is filled with lubri-
cant.